Scratch Build Na'ir al Saif

[Attila]

Thanks everyone.

This part, the chassis, is actually slightly larger than the the chassis for CX1. This is due, among
other things, to the giant size of the GFX card.


I'm posting this now, even though just one of the struts isn't even complete, because making
four of these things will take a lot of time, so I won't be back for a while.

First a pattern needed to be made in some scrap alu, to transfer the design to the alu bar.



Much easier to cut the pieces with a power saw.



Then the design is tranfered over onto the bar.



A couple of guide holes drilled.



Now this thickness (12mm) is testing the limits of what I can cut with the jigsaw. The work-
piece is getting very hot and even a new blade lasts only a short time. The cut is very rough.





The filing is also very slow. About a third of the time is spent resting my right arm.
So having spent the whole of my available time on this, the first arm is not even close to
being finished but I can get a good look at how it goes with the rest of the chassis.







Well, I like the look of that very much. It's even concievable that no pads are needed thus
reducing the height a little. But I'll have to think about that a bit.


EDIT

I remembered the cut-outs for the rear support so I tried the large one for the pads.
It may be OK with large diameter, low profile pads. Hmmm.





Back soon.

[stonedsurd]

If you get rid of the pads, you'll have to make the center section (where the 4 struts meet) slightly less pointy (and shorter).

Wait, I'm giving advice to you. Obviously you thought of that

[Editor22]

Damn this log just gets better and better, I dare anyone to read it and not feel inspired to go out and create something. On a side note I bet your filing arm is going to look something like this when your done on that 12mm bar! just crazy!

[The_Gnu]

I love your projects, shows of your patience and attention to detail and im impressed by how fast this project is developing. Good work

Originally Posted by Editor22

... I bet your filing arm is going to look something like this when your done on that 12mm bar! just crazy!

Naah... I would guess more like this

[Dot_Kappa]

It's simply a pleasure looking at your worklog!!
On each update the "modding-rod" is set to an higher level

[Attila]

Originally Posted by stonedsurd

If you get rid of the pads, you'll have to make the center section (where the 4 struts meet) slightly less pointy (and shorter).

Yep!

Originally Posted by Editor22

Damn this log just gets better and better, I dare anyone to read it and not feel inspired to go out and create something. On a side note I bet your filing arm is going to look something like this when your done on that 12mm bar! just crazy!

Haha, thanks. Yes I try and go to great lengths in the log to show that anyone can make
nice parts, right now with only a few tools and some sweat. I think it would be
great if more viewers became active modders and builders.

Oh and as far as the filing is concerned, it's good to think of something so you don't
get bored. I think of CNC machines a lot.

Originally Posted by The_Gnu

I love your projects, shows of your patience and attention to detail and im impressed by how fast this project is developing. Good work

Thanks mate.

Originally Posted by Dot_Kappa

It's simply a pleasure looking at your worklog!!
On each update the "modding-rod" is set to an higher level

Thanks a lot Dot.

[talladega]

Originally Posted by The_Gnu

I love your projects, shows of your patience and attention to detail and im impressed by how fast this project is developing. Good work



Naah... I would guess more like this

that must be Mankz!



kingnewby, what kind of blade do you use in your cutoff saw?

[Attila]

That's a carbide tipped 10inch blade made for alu. The teeth have a negative hook angle.
Wood blades have the teeth angled towards the direction of rotation, a positive hook angle.

[oliverw92]

For cutting that thicker stuff with the jigsaw have you considered a different type of blade? I use a ceramic blade when cutting thick aluminium and it eats through it like butter, leaving a very clean finish that just takes a little sanding. They look like this:

[AnG3L]

Wow wow wow!!! OMG! (Awesome vocabulary here huh?)

[Blooddrunken]

You inspired me so much with your logs, I started again with modding after 5 Years of pause and just reading.

[Mankz]

Originally Posted by talladega

that must be Mankz!

[stonedsurd]

Originally Posted by Mankz

[Locknload]

Hi again old newby,
Just a thought you could also use an Electric ceramic tile cutter on the aluminium, these also come with a little water trough which makes the process a lot smoother as it lubricates the cutting process they are only cheap to buy...plasplugs make a version of it.

[Attila]

Originally Posted by oliverw92

For cutting that thicker stuff with the jigsaw have you considered a different type of blade? I use a ceramic blade when cutting thick aluminium and it eats through it like butter, leaving a very clean finish that just takes a little sanding. They look like this:

Thanks for the tip. I'll go and get some of those blades, I'll try anything that can
make life easier.

Originally Posted by AnG3L

Wow wow wow!!! OMG! (Awesome vocabulary here huh?)

Haha, thanks Ang3L.

Originally Posted by Blooddrunken

You inspired me so much with your logs, I started again with modding after 5 Years of pause and just reading.

Thanks, I'm happy that you got some inspiration from this.

Originally Posted by Locknload

Hi again old newby,
Just a thought you could also use an Electric ceramic tile cutter on the aluminium, these also come with a little water trough which makes the process a lot smoother as it lubricates the cutting process they are only cheap to buy...plasplugs make a version of it.

Thanks a lot L&L. I'll look for one of those next time I'm down at the hardware
Barn.

I've done most of the shaping for the support struts. The top curves were easy to get nice
but I'm having difficulty in getting a nice smooth curve on the underside. Just have to keep
at it.

Trying to speed things up a little, a 50 grit sanding disc was used to remove the bulk of the
material from the top of the three remaining struts.





Here are some pics of what it should look like. I've just arranged the struts roughly and please
excuse the uneven curves on the lower sufaces.













Back soon.

[stonedsurd]

Uneven? You call that UNeven?



It's looking great man. I rather like the angular nature of the ends of the struts but if you're incorporating round shapes elsewhere (the fans) then perhaps you might want to rethink adding the pads - just thin 1/4" or 1/2" ones.

[Attila]

Thanks, yes I'm thinking about rounding off the ends of the struts and yes again,
large, low profile pads are the way to go.

[Kylevdm]

DUDE! This build has come along sooo much since I last saw it! Loving all the aluminium! I love my aluminium! <3

[shomann]

You would swear this was done by CNC oldnewby. Really loving the build so far. Rock on.

[skreenname]

Originally Posted by stonedsurd

Uneven? You call that UNeven?



It's looking great man. I rather like the angular nature of the ends of the struts but if you're incorporating round shapes elsewhere (the fans) then perhaps you might want to rethink adding the pads - just thin 1/4" or 1/2" ones.

Of course it's uneven!
Can't you see the right front strut is 12nanometers thichker than the left at the same spot?!


@Oldnewby
Stop being awesome.
You're making me want to mod more stuff.