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Scratch Build – In Progress Acronym

Discussion in 'Project Logs' started by Achron, 28 Nov 2009.

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Which faceplate design do you like? (Faceplates on page 6)

  1. Don't change anything!

    29 vote(s)
    14.9%
  2. Faceplate 1

    12 vote(s)
    6.2%
  3. Faceplate 2

    53 vote(s)
    27.3%
  4. Faceplate 3

    12 vote(s)
    6.2%
  5. Faceplate 4

    51 vote(s)
    26.3%
  6. Faceplate 5

    14 vote(s)
    7.2%
  7. Faceplate 6

    29 vote(s)
    14.9%
  8. Faceplate 7

    27 vote(s)
    13.9%
  9. Some other design!

    14 vote(s)
    7.2%
Multiple votes are allowed.
  1. Achron

    Achron Cad Pro Quo

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    Hello folks! Hope everyone is ready to gear up for the holidays, I know I am. This may be one of my last posts until the new year, I'm flying home (across the US) for Christmas break starting Friday, so I'm busting my butt to get a lot of stuff done before then. So, enjoy the show!

    We got a new granite inspection table this week. This thing is incredibly heavy (I'm guessing over 1000 pounds):

    [​IMG]


    Side Pieces:

    This weekend I've been working on the side pieces and the backplate. If you recall my design, I have to make to of the following pieces:

    [​IMG]

    These pieces were rather big, so the aluminum was hard to come up with. We had a piece of aluminum 9.75" in diameter (cylinder) and almost 3" thick. I couldn't cut the piece in half to make both of the sections, but if I cut it 9mm off center and then stepped across the centerline 9mm to the other side, I could fit the 2 pieces in!! Yay for me!

    Also...this thing took forever to cut in half. The aluminum bandsaw blade snapped (and I about pissed myself) so I had to use the steel bandsaw. Took about 30 minutes to cut through :wallbash:.

    This is how big this chunk of aluminum is:

    [​IMG]

    Putting it in the CNC, I faced the top and the sides to get a nice 0,0,0 position:

    [​IMG]


    After facing the piece, I cut an inch or so off of the other side to get the piece closer to the final size. I milled the alignment holes in each side, then I roughed it out (CNC go go!).

    [​IMG]

    [​IMG]

    [​IMG]

    Then I finished the piece with a long, small ball end mill.

    [​IMG]

    [​IMG]

    Seems like I forgot to take a finish shot. That'll be in my next update.


    Motherboard Backplate:

    Since I didn't want to spend all night at the machine shop, I chose something easy. Here's what the piece should look like:

    [​IMG]

    Cut the piece out of 1/16" aluminum:

    [​IMG]

    Cutting the pattern!

    [​IMG]

    [​IMG]

    [​IMG]

    Prying the piece of aluminum off of the plexi (very good double sided tape) was a pain in the butt.

    [​IMG]

    Did I ever mention I hate sanding aluminum? That gunk sticks to your hand.

    [​IMG]

    Final shots!

    [​IMG]

    [​IMG]

    [​IMG]
     
  2. Interloper

    Interloper Faux Pro Modder

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    Holy sweet mother of modding! That is a HUGE chunk of aluminum!
    I feel the sudden urge to touch it.

    This is one epic project, I love it. Keep it up!
     
  3. murtoz

    murtoz Busy procrastinating

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    Be careful of your choice of words around here.... things *WILL* be taken out of context! ;-)
     
  4. Angel OD

    Angel OD Pump Killer

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    This is looking great! /Subbed!

    Btw, to get aluminum off of your hands, just use normal dishwasher soap, with lemon aroma! The lemon is the secret! :thumb:
     
  5. Koolpc

    Koolpc Minimodder

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    What an awesome thread. You are surely gifted mate. Can't wait to see the finished article!
     
  6. Achron

    Achron Cad Pro Quo

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    Thanks for the advice. We actually have a parts cleaner, with I'm assuming what is degreaser, and that stuff just takes it right off. It heats the water up really hot though, so it's a pain to wash your hands in. The powder soap also works great.

    By the way, I love your Wii mod :-D, and thanks for the support!
     
  7. Achron

    Achron Cad Pro Quo

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    Top Assembly of Case

    So since I'm leaving on Friday and I'm busy Thursday night, I'm busting my butt to get everything ready and started!

    I got my plexi today!!

    [​IMG]

    I do have one question for you guys before I get started here. I'm going to have pins connecting the pieces to align them. I was thinking stainless originally, but I have a rod of brass I recently acquired. I'm up in the air as to which one to use (I need 26 of them, so both is probably out of the question). Any help?

    [​IMG]

    [​IMG]

    [​IMG]

    Anyway...here's what I'm doing with the top piece to CNC the inside. I put the blocks together as shown here, and layered it with the plexi I cut out.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Here's some pictures with the plexi sitting on top.

    [​IMG]

    [​IMG]

    [​IMG]

    I had to pin the alignment holes to see the correct diameter. The stainless and brass rods are 1/4" thick, so I was expecting to shave just a tiny bit off. Turns out I'll be taking them down to 0.265" or so.

    [​IMG]

    I started a nice process in which to make the 26 little pins. What a pain!! I lathe it down, chamfer one end, polish it, part it, then set it aside. After all are done, I put a stop in the chuck of the lathe, machine one to the correct length, then face all of the rest of them, then chamfer them! Yikes!

    Test pieces:

    [​IMG]


    I'll be updating you guys tomorrow, hopefully. The CNC process for this piece will be an all day venture, so we shall see how it goes! Here's a shot of the solid model just to give you guys an idea of how this will look after it is done:

    [​IMG]
     
  8. Interloper

    Interloper Faux Pro Modder

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    EXACTLY what I was hoping for....... :)
     
  9. Nutman

    Nutman Never stuck with stock

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    Dunno why I didn't subscribe to this one before, but here I go!
     
  10. rocketjumping

    rocketjumping DIY ADDICT

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    At least no one can steal it. It looks like it's shaping up into a two-person lift from all the solid aluminum!

    Case looks really sweet though, keep it up!

    Wtb access to a machine shop for personal use...
     
  11. Cheapskate

    Cheapskate Insane? or just stupid?

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    Friggen hell, man! This is going to rule! (no... It already does.:D)
    How awesome is a computer project that requires steel-toe boots?
    -Good call on the stainless pins. The brass would have darkened over time. I'm curious to see how you are clamping all this down.
     
  12. Achron

    Achron Cad Pro Quo

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    Happy new year everyone!

    Big update here. Time wise, not quite content wise. These next pictures are over the course of a few days, just to complete one thing!

    If you can remember, I had the 3 solid pieces of aluminum lined up ready to CNC. Well, here's the process!

    Roughing
    [​IMG]

    Roughing Mounted
    [​IMG]

    Roughing Closeup
    [​IMG]

    Roughing No Flash
    [​IMG]


    Finishing in Action
    [​IMG]

    Finishing in Action
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    Finishing in Action
    [​IMG]

    Finishing in Action
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    Finishing in Action
    [​IMG]


    Finished Aluminum Pieces
    [​IMG]

    Finished Aluminum Pieces
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    Acrylic Set up for Machining
    [​IMG]

    Roughing of Acrylic
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    Roughing of Acrylic
    [​IMG]

    Roughing of Acrylic
    [​IMG]

    Roughing of Acrylic
    [​IMG]

    Roughing of Acrylic
    [​IMG]


    Finish Passes
    [​IMG]

    Finish Passes
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    Finish Passes
    [​IMG]

    Finish Passes
    [​IMG]

    Finish Passes
    [​IMG]

    Finished Acrylic Section
    [​IMG]

    Here's a finished shot showing some improvements on sanding that need to be done (finished with 620 grit, will do more when I get some).

    Finished, Sanded
    [​IMG]

    Finished, Sanded
    [​IMG]

    Finished Closeup
    [​IMG]


    Happy New Year!
     
    Cheapskate likes this.
  13. wE-eViL

    wE-eViL Sparky

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    Very nice work.
     
  14. woody_294

    woody_294 Wizard Ninja :P

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    Good god I hope I get access to a CNC machine at some point in my life, nice work and happy new year!
     
  15. null_x86

    null_x86 Thread Closer

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    damn, epic start. Sub'd!
     
  16. ringo

    ringo What's a Dremel?

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    very cool, a cnc machine make some things easier. Very good work.
     
  17. stuartwood89

    stuartwood89 Please... Just call me Stu.

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    I reckon this case will have cost you more than the rest of the hardware.
     
  18. Achron

    Achron Cad Pro Quo

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    If that's not the case, then what's the fun? :lol:

    Although, with a slim blu-ray slot drive, the price jumped up a bit, so I may be safe.
     
  19. Angel OD

    Angel OD Pump Killer

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    3D milling Cheesecake! :thumb:

    How long did it take to machine the 3D aluminum?
    And what software do you use?

    BTW, still loooooove this one! :rock:
     
  20. Cheapskate

    Cheapskate Insane? or just stupid?

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    +1 on what AngelOD said, ('Specially the looooove part.)
    I'm currently shopping for CAM software, and the prices are a direct hit on the groin area.
     

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