Scratch Build – Complete Cygnus X1.

bumpty bump bump

 

Sure, make it look like my fault

 

Sorry, but it wasn't meant as a tease, just pointing out that the lovely contrast
between the wood and the alloy will be preserved on the outside.


It's time to start making the top of the case now. Although I've known how this will
look for months the details still need to be worked out. I have two options as far as
the frame is concerned, alloy or wood, and I can't really pick between them so I just
started to make it out of alloy and if that's not to my taste then I'll have another go
at it in wood.

So, there is a wood insert that makes up the nose (where the top meets the front).
This is the work piece and you are looking at it from the bottom. It needs to be shaped
with a curve over the front and top and more material will be removed from the rebate.



The nose will be sandwiched between two alloy plates. I'm using 3mm here because
I have this laying around but it probably should be thicker, not for strength, but looks.



The profile is traced onto the work piece.



And cut out with the jigsaw.



Then it's quickly filed down close to the line.



And then, much more slowly, it's continually filed, put in place and filed ever more
slightly until it matches the curve of the panel.



Still slightly too high.





So I'll keep going with this and make the other side, back soon.

 

Ohh, nice idea!

 

MoMMMMMMMMMMMM He's doing it again! Making stuff nobody can match.

 

Mod of The Millennium for sure

 

amazing just doesnt cut it..

 

Haha thanks a lot guys.


Well that part I made yesterday can go in the trash can.
I forgot to include the extension on the front for the nose.

So I made two new pieces today (correctly).
These were left high until they are linked up to form a unit.



To join the two sides, instead of using bar, I thought it would be good to save some
weight and make the links out of "U" channel. I've gone into more detail here in case
someone else may want to do this. It really is a simple method and gives a very nice
custom part. You can make this two ways, bend the tab over the sides or, bend the
tab between the sides. One will give you the look of a "part" and the other will give
you the look of a piece of "U" channel.

This is 10mm "U" channel. First mark up and cut away the sides.





Then file the sides and remaining tab square.



Then, with a screwdriver (or other tool that fits in the channel) secured in the
vice, tap the tab over.





Once the bend is started, I hold the part in my hand and hammer the tab home.



Then after some more filing you are left with a nice part that is surprisingly strong.



This channel excepts, exactly, a small dome nut. Very handy.



I just need to make another for the back.




Another benefit is that the material is 1.6mm thick, so if you make the part .6mm
or so bigger, you are able to file it down to fit perfectly and adjust for slight out
of square and still have enough material for strength.

 

looks great!

 

Damn awesome work mate, very very nice work. The pics of the two sides attach reminds me of those new espresso machines lol.

 

Your handling of those extruded U-channels is superb. I've doodled with 10mm rectangular tubing, but never got such clean results. You are truly a master.

 

Every day it just gets better and better.

 

Ah, my fav project of late
Feels good to be back, and great work oldnewby

 

Thanks everyone!


My wife just started a new job so if I didn't have much time before it's double now.


The piece of wood I cut for the nose turned out to be too small, so I had to make it
up out of two pieces. This was shaped in the usual way.







The part was left high, as is everything at the moment until it's assembled. The
curves are a little too pronounced and as you can see, some adjustments needed
to be made to the side panels.



Back when I can.

 

I hereby propose that the mods jump into the control panel and rename oldnewby's account to 'oldmastercraftsman'. All those in favour, say 'I'.

And +rep the crap out of him, only 2 bars and he has built something like this?? A travesty.

 

QFT, I and +rep for both of you!

 

I!!!

Need I say more ???

 

I

MY vote for moty has gone, I think.

 

Well said, sir!

Also, "I"

 

And I