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Old 5th Apr 2011, 05:52   #181
Waynio
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Originally Posted by Attila View Post
Thanks. I'm still working but the parts that are being made now take a long, long time.
Yeah it does look a time consuming part but does look in awesome perfect shape mate .

The 1 thing I dislike most about only being happy with 99.9% perfection is it really kills a budget the time consumption doesn't bother me too much with me having plenty of free time but breaking a budget does & I've gone way over budget already, in fact so far over I'd much rather not add it all up .
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Old 5th Apr 2011, 08:07   #182
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Thanks for the replies.

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Originally Posted by Javerh View Post
How do you make those inner radiuses? I'm having a hard time trying trying to file a perfect circle consistent along the edge.
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Originally Posted by Razer2007 View Post
Don't want to speak for Atilla but doesn't he use round files?
Yes, the radii are made with a round file.



This file is tapered, but the greatest diameter of 7.8 mm is perfect for making these radii. This file is also fairly coarse, so it cuts very quickly. You need to always maintain perpendicularity to the surface you are filing in order to get a good finish. I think the position of the vice has a lot to do with being able to maintain square edges.







Here's a photo of the inside edges done.



Using a variety of files, any shape can be accurately made.











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Old 5th Apr 2011, 08:15   #183
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Nice work showing step by step process. Looking good
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Old 5th Apr 2011, 08:49   #184
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Old 5th Apr 2011, 09:27   #185
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Woow, u're work realized with files is amazing!!!

What is the thickness of the alu' tray? I've the impression that is a little bit thick no?

Very very very good job Attila!!
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Old 5th Apr 2011, 10:12   #186
Waynio
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Chunky good looking panel, most definitely built to last I'd guess it's 10mm thick .
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Old 5th Apr 2011, 10:41   #187
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Quote:
Originally Posted by craig - toyoracer View Post
Nice work showing step by step process. Looking good
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Still drooling!
Thanks guys.

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Woow, u're work realized with files is amazing!!!

What is the thickness of the alu' tray? I've the impression that is a little bit thick no?

Very very very good job Attila!!
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Chunky good looking panel, most definitely built to last I'd guess it's 10mm thick .
Thanks. Yeah these two parts together with the bottom tie plate are 8 mm. These parts need to be rigid and strong. The whole radiator assembly including the cover and the front of the shell with filter tray and intake grille will 'hang' off the front bulkhead. The rear part has to support the PSU 'hanging' below the central plate, all without flexing. Also, 8 mm is the minimum thickness that can be used for face to edge fixing with machine screws. Like Na'ir, this method of fixing will give a very strong and good looking method for making the main support structure.
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Old 5th Apr 2011, 11:01   #188
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So no need for any kind of bar frame supports, got it & yeah that sure does make for a super high quality clean look (the Attila trademark) love it .
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Old 5th Apr 2011, 12:24   #189
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Sweet work Attilla , I bet that took a while due to the thickness of the alu.
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Old 5th Apr 2011, 17:01   #190
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Man, I don't have the patience to hand file aluminum parts. Your work is truly outstanding.
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Old 5th Apr 2011, 20:20   #191
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Very, very nice work.

And, yeah - it's not too hard to file like that. Only, use the inside of your head, take your time, think about ways to create nice, straight edges, be quite critical as you go along and work slowly in order to be able to do quality checks on a regular basis.
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Old 6th Apr 2011, 10:38   #192
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Awesome. The painstaking attention to detail and patience to achieve those oh so so clean lines is astounding
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Old 7th Apr 2011, 11:13   #193
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Quote:
Originally Posted by Waynio View Post
So no need for any kind of bar frame supports, got it & yeah that sure does make for a super high quality clean look (the Attila trademark) love it .
Thanks mate. Yeah I'm over the frame thing.

Quote:
Originally Posted by riekmaharg2 View Post
Sweet work Attilla , I bet that took a while due to the thickness of the alu.
Thanks. Yes it all takes time. But it's worth it in the end.

Quote:
Originally Posted by llamafur View Post
Man, I don't have the patience to hand file aluminum parts. Your work is truly outstanding.
Thank you.

Quote:
Originally Posted by Nutman View Post
Very, very nice work.

And, yeah - it's not too hard to file like that. Only, use the inside of your head, take your time, think about ways to create nice, straight edges, be quite critical as you go along and work slowly in order to be able to do quality checks on a regular basis.
Haha, do I detect a note of sarcasm here.

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Originally Posted by RonanH View Post
Awesome. The painstaking attention to detail and patience to achieve those oh so so clean lines is astounding
Thank you.


OK, once the two 'bulkheads' are almost finished, a few things still need to be done. The front part is significantly narrower than the rear. So I need to centre the two and fix them together. This is because, even though I measured, cut and filed very carefully, they are still not the same height. Also, some of the projections you can see are where the central plate fits. These have to be exactly the same height.



Here you can see that one piece is about 0.5 mm or so too big. So this must be taken down to match the other part. In truth this is not really that critical but it's better to have them as close as possible.





Next, these are the projections (not all of them) that hold the central plate. these are also not the same height.



But to get in there, I need to 'mod' a file.





I've used this file on every project and it's very flat, so it will be perfect to even things up in here.



Here you can see the difference in height.



So carefully, these are all brought to same height, all the while continuously checking that the edges are square.







It gets progressively more time consuming as all the surfaces have to be brought down to last little 'low' spot.



OK, now the fun part where I can get a first glimpse of what the chassis will look like. Now I always like to take measurements directly from the work, so in order to find out how big to make the lower tie plate, I need to assemble the bulkheads to the central plate. Because the two bulkheads are different sizes, supporting the central plate and then 'hanging' the two ends of it is the best way to take the measurements.





And once the measurements are taken (and checked three times) the lower tie plate can be marked up on some 8 mm plate.



But I have to go and pick up Anika now. Back soon.
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Old 7th Apr 2011, 11:25   #194
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Great workmanship! Where do you buy your files? Is the flat one a simple mill file or is it one of those specially made for alu?
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Old 7th Apr 2011, 11:29   #195
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Old 7th Apr 2011, 16:13   #196
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Well Damn!!! That is how it's done? Next mod needs to be named Flawless Execution.

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Old 7th Apr 2011, 17:11   #197
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The cast iron set you have!
I would have been very hesitant to chop my favorite file up.
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Old 7th Apr 2011, 17:31   #198
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Yeah I wonder too, how did you cut up your file?
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Old 7th Apr 2011, 17:52   #199
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Yeah I wonder too, how did you cut up your file?
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But to get in there, I need to 'mod' a file.

Looks like an angle grinder with a cutting disc to me. That should do the trick, even on tool steel.
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Old 7th Apr 2011, 19:30   #200
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Files are about 10 bucks a pop from mcmaster, I don't think its a travesty to cut the handle off of one
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