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Old 21st Feb 2012, 19:11   #161
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Now I've had a needed sleep I can make better sense I think remember got man flu & just carried on doing this.

Man flu is the flu between a cold & the flu not the full on knock you out type flu.

I still think I'm on the right idea for getting rid of the teeth marks, if I cut with 1 or 2 mm space away from the mark like you do when you have filing in mind filing would be an option but if I went at it as it is I know I'd botch the edges with it being so precision cut even if I do go at it really careful or at least I believe so.

The folded over piece of sand paper worked great but just needs something stiff inside it so it can do it faster & a lower grit than 240, too high to start off with.

I got the idea of this ages ago from using really thin strips of sand paper held tight on both ends & pulling back & forth through cut out pieces where files couldn't get in not even needle files & was a highly effective way of smoothing internal edges & really wanted to use the base of the idea on a power tool to speed it up & take the monotony out of it & I'd say this is the way.
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Old 21st Feb 2012, 19:21   #162
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I don't know if you can get them over there, but a company named Olson makes sanding strips for scroll saws. You may want to look into those. I have some and they would work well for this kind of thing.
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Old 21st Feb 2012, 19:37   #163
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Wow, I'm surprised a scroll saw can do all that. I would have figured that you'd need a lot more tools than just one for a mod this damn amazing.


Keep it up
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Old 21st Feb 2012, 20:05   #164
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Nice stuff sleepy head. It's clear I need to bag myself an electric scrollsaw.
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Old 21st Feb 2012, 20:13   #165
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Originally Posted by voigts View Post
I don't know if you can get them over there, but a company named Olson makes sanding strips for scroll saws. You may want to look into those. I have some and they would work well for this kind of thing.
Been aware of them but not seen any but not looked much for them really, it would be worth getting some even if it was to clone them, I do still have a few more tricks to try out though, quad layer, card in the middle, blunt blade in the middle or even 0.5mm stainless steel strips, each further thing I've tried has had more success than the last so I think I'll get there.

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Wow, I'm surprised a scroll saw can do all that. I would have figured that you'd need a lot more tools than just one for a mod this damn amazing.


Keep it up
Thanks mate it is a bit crazy so far only needed that & a drill oh & jigsaw to make that huge 3mm panel into smaller sizes honestly though the stand panels were difficult to do because of the lack of front & sides of the table & took ages, I'm seriously considering buying some more 3mm alu to double up or a 6mm sheet & make a new table to mount to the saw so I have much more front & sides to it, it's the only thing that lets it down, loads of back table but vitually no front, I have good reach so an extra 3 or even 4 hundred mm front would be fine for me & would stop pieces from rattling about while cutting.

The extension I made would have been good but the legs used for it wasn't able to cut fully with a chop saw so they are not all equal which makes for a very crap extension so it's either make a new one which is definitely the cheaper option or just go & make a replacement table, I know I should do 1 or the other so I can cut better.

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Nice stuff sleepy head. It's clear I need to bag myself an electric scrollsaw.
You can get foot pedal powered ones too I still have that first one sat in it's box, just needs a cheap part to fix it.
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Old 21st Feb 2012, 21:29   #166
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Tell ya what mate, thats some really neat and tidy handiwork. That 10mm Ali is going to give this build a real solid look to it and with that thickness it'll not doubt be solid as a rock.
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Old 21st Feb 2012, 23:04   #167
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Tell ya what mate, thats some really neat and tidy handiwork. That 10mm Ali is going to give this build a real solid look to it and with that thickness it'll not doubt be solid as a rock.
Thanks Jeff it was a mission the first time around & then realised the htpc sides were about 3mm too big in all areas so that's going to be used for a spare rig I'll make to sell after this build so had to re do them but now I have the chunky stuff done & still full of man flu & know what I need to do to smooth all the tooth marks out I'm going to sneak my bros 580 out of his rig for a couple days & enjoy some sli 580 awesomeness.

Keen to try metro 2033 & quite a few other demanding games fully maxed at 2560x1440.

He's going to be selling all his components & I'll be doing him a low power compact htpc because he realised he doesn't care much for gaming so I have dibs on the 580 so if I think it's worth buying a 2nd one I will, it has the same 3rd party cooling as the one I got for mine, an accelero extreme, big & bulky but the temps are nice on it & it's far more quiet than the stock cooler.

By the time I've had a play around with if it's worth going sli I will probably be feeling a ton better & ready to get stuck back into this project. Couple of days break & I should be much better.
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Old 22nd Feb 2012, 01:49   #168
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Well that wasn't a simple plug the extra gpu in & go.

I had to remove the 8pin atx cable from the system because it has a 12 pin plug with 4 empty pin slots that goes into the psu, so I took it out & put it to my scroll saw to cut the empty 4 pin holes off, also had to remove the clip piece from it so it would plug in, this allowed me to plug the extra dual 8pin pci-x cable in so I'm up & running with 580 sli now.

I'll get back to producing updates in a couple days.
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Old 22nd Feb 2012, 04:10   #169
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That was a very short lived experiment about 2 hours.

Already put my config back to single 580, not impressed by sli just like bit-tech & custom pc aren't, I've tried cross fire before & was disappointed with that also, so I'll definitely stick with a single powerful gpu from now on.

Completely underwhelmed by sli 580's I'll get back to modding tomorrow.
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Old 24th Feb 2012, 19:18   #170
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Total lack of updates lately.

My enthusiasm to keep at it burnt out quite a bit so had to let it build back up absolutely need enthusiasm to do this stuff all that 10mm alu took the steam out of me, was already burnt out after the first load & then had to re do the htpc panels.

I know it looks like it's just guiding the material along the saw but you have to hold it down nicely almost like a clamp while you guide it along ultra slow otherwise it would bounce up & down violently, I could use the hold down piece the saw comes with but to have it hold it tight causes it to scratch heavily so I took it off not to be used which makes it harder to do but keeps the work free from bad scratches that would be really difficult to remove.

So yeah I will get progress flowing again now & already made a couple of really good drilling aids that I'll be able to clamp to work pieces to drill 100% where I want to.
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Old 25th Feb 2012, 00:51   #171
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I think that Man-flu may have something to do with it.


Take your time Wayne you know this is a long-haul project. Maybe you will have the cutting done by the time the summer heat comes.
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Old 25th Feb 2012, 09:36   #172
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I think that Man-flu may have something to do with it.


Take your time Wayne you know this is a long-haul project. Maybe you will have the cutting done by the time the summer heat comes.
Yeah it would have a fair bit.

I aim to get the cutting of the panels done in less than 2 weeks, random deadline for a laugh seriously I will aim to do that.

Just put an order in for a big sheet of heavy duty self adhesive velcro hook so I can change my disc sander from adhesive discs to velcro ones because there is more choice of grits & they will be quick to change & a bunch of discs in 60, 120 & 320 grit.

Already got a 75mm drum sander but ordered a 12.5mm & 25mm one, they are great & can use any sand paper on them.

The shop I ordered from for some of the bits could take 2 weeks to deliver so I'm using that time to blitz through the cut work, done the 4mm stuff already today.

Also a few extra packs for grits that I'm missing from my sanding supplies of wet & dry of 60, 120 & 400, then I'll have a good range of steps for any sanding work.

Won't be doing any sanding though until all the panels are ready for it which I aim to have done by the 10th of March, 2 weeks from right now.
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Old 25th Feb 2012, 10:49   #173
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Slow down eager ill beaver!
And good luck, sounds great.
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Old 25th Feb 2012, 12:38   #174
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Sounds like you're having just as much fun as me , with all that sanding. That scroll saw is a very nice bit of kit
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Old 25th Feb 2012, 12:43   #175
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Quote:
Originally Posted by Waynio View Post

I know it looks like it's just guiding the material along the saw but you have to hold it down nicely almost like a clamp while you guide it along ultra slow otherwise it would bounce up & down violently, I could use the hold down piece the saw comes with but to have it hold it tight causes it to scratch heavily so I took it off not to be used which makes it harder to do but keeps the work free from bad scratches that would be really difficult to remove.
Thinking about this problem I though could you not fit a wheel to the hold down then though hmm it would have to castor then thought and be sprung .... all getting a bit complicated .

Then I thought how about one of these ....



Just the ball part obviously It would apply pressure and leave the part free to move ???? Would it mark the ali ?
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Old 25th Feb 2012, 13:55   #176
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I admire your patience bro. I really do! Now more pr0n plox!!!!
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Old 25th Feb 2012, 17:01   #177
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Quote:
Originally Posted by KidMod-Southpaw View Post
Slow down eager ill beaver!
And good luck, sounds great.
Slow down

Quote:
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Sounds like you're having just as much fun as me , with all that sanding. That scroll saw is a very nice bit of kit
Got a good bit of sanding ahead of me you have a whole lot of acrylic to do on yours eh really time consuming & severe boredom inducing this why I'm working on ways to really speed it up come to think of it I haven't subbed to your log yet, will do after this post.

Quote:
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Thinking about this problem I though could you not fit a wheel to the hold down then though hmm it would have to castor then thought and be sprung .... all getting a bit complicated .

Then I thought how about one of these ....



Just the ball part obviously It would apply pressure and leave the part free to move ???? Would it mark the ali ?
I only really have that problem with thick metals really, thinner stuff scrolls much nicer, chunky stuff is a bit of a battle though, cheers for the suggestion though bugeye, I think anything metal holding pressure on material would mark it so you just need to tame the furious bouncy metal.

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I admire your patience bro. I really do! Now more pr0n plox!!!!
It's nothing much, I just keep in mind the end article & it makes it bearable cheers. Alex
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Old 25th Feb 2012, 17:03   #178
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Due to popular demand, picture progress report.

Started back up today after a little break to recover from man flu & lack of enthusiasm due to spending absolutely ages cutting the 10mm panels.

Got all the 10mm, 4mm cut & 1 of a heck of a lot of the 3mm panels done, it is getting easier but there is some high detail 3mm panels to be done & have no idea how long those might take I would do those next but I could do with getting a stronger spray adhesive to make sure it stays held down for the whole panel, soooo many cut outs to be done on them & this spray adhesive is only any good for simple panels.

Also shown here is the drill helpers, these particular ones are for drilling spot on on bars & on edges, I'll make a bigger one for big flat panels, will help make sure every single mount position is 100% perfect on edges of the 10mm panels & on any panels with a normal power drill.
















On to easier thickness of 3mm now, then 2mm then 1mm then adding all the drill mount points then an epic sanding session, then acrylic which cuts incredibly easy on the saw then gluing some of the acrylic parts together, then hmmmmm woooooooo hoooooooooooooooo.

Because I've gone to such lengths on the design it would probably be able to be mass produced also but have no plans at all for that but it is my most complete design so far.
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Old 25th Feb 2012, 17:49   #179
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Parts:

velcro + sander: I had an image of a horrible, afro-related accident.

Hold down scratching: HDPE is your friend. You know that soft plastic they use on shampoo bottles? A layer of that on the hold down will stop the scratching. Of course, if little bits of aluminum get under it, it cancels that.
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Old 25th Feb 2012, 17:54   #180
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Thats some really nice progress, from the pics the sawing looks like cnc quality.

Bet ya glad you started with the 10mm, should be easier now your onto thinner thicknesses.

ive used 12mm ally on my last metal build and that makes it heavy, so im guessing yours is gonna get heavy also, even though its a mini build as such.

I can actually see how its gonna go together, although youve only got panels as such yet.

I always thought it would maybe a good idea for all the modders on here to work on a project together (prob be too much not like that, like this though) may end up in a bit of a brawl, so maybe not?.

Oh, and stop with this flu and nonsense, men dont get ill .

Carry on.
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