I am looking at replacing a fan grill on my side panel, with something nicer looking. Right now, I have a square of perforated metal (aluminum, often called modders mesh). It doesn't look to bad, but could look a lot better (no, I didn't try to cut a circle!) I am looking at possibly trying to cut, from some sheet aluminum, a fan grill, with the USMC Eagle and Anchor logo. One reason for this choice of logos, I have a brother in the USMC, and I am contemplating trying to do a Marine Corp themed case sometime in the future. Anyone have any experience with cutting your own fan grills? With access to nothing more than a good Dremel tool? I was thinking of having a custom laser-cut done, and found a few places that will do custom laser or water jet cutting, but I'm afraid to find out prices.
When you'll be working with a small object like a fan grill, you have to get it cutted by a laser or waterjet. Otherwise it probably be ugly. And yea, the pricing is shitty. But why don't you get a deal with one of the employees ? Bring a sixpack and some cash, and get him to cut it out a afternoon. Some of 'em will do it. But be careful, it's illegal
Unfortunately, I don't know wanyone who works in a shop, that has a waterjet or laser-cut rig. Wel,, maybe I'll pick up some thin aluminum forom HD or Lowes, cheap, to try it out, and see if I like the results. If not, I'm only out a few bucks, and time. If I like how it turns out, I can always track down some heavier gauge metal, and work on it.
Doesn't have to be. http://forums.bit-tech.net/showthread.php?t=74632 I managed to this, and I am definately no dremel professional. It was done with a large, chunky dremel imitation - no flex shaft. It takes time thats all. If I were you, I'd some 1mm aluminum, cut it up into several pieces fitting your needed dimesions, and have a go at it. Draw the design you want, _MIRRORED_ on some cardboard first, and cut out so you have a template. Place it on the aluminum, take a pen/pencil and draw along the edges. Then. it's just to have a go... The side you're cutting from might look kind of nasty when you're done, but thats why you draw it mirrored. The other side is what's supposed to show. It's all a matter of trying, patience and trying again if you fail. Happy modding!
Yeah, I'm thinking of giving that a try. I also started thinking of using some of the acrylic sheet I've already got, and then working with that. Nice thing I can see about using acrylic, is I can work in the fine corners with a sharp knife, and cut/grind the bulk of it out with a Dremel. If nothing else, this gives me a fun spring project to try in the spring, when it warms up, to breakin my new Dremel....
Don't do it with 1mm aluminum... Will be way to thin, and bend if you look at it I personally would prefer 1.5 or 2mm. Or steel, but working with that is almost impossible, without proper tools (which are expensive). But good luck, and post some pictures, if you succeed
i've made fan grills using a scroll saw. You can make them with a dremel, but it is a lot harder. Good Luck
Now a scary thought... I went looking for laser cutting equipment, and came across a desktop laser cutting/engraving rig, for about $8K. Plugs into a PC like a USB printer, and can be printed too. Apparently it was even featured on TechTV. Downside is, while it can cut, it isn't listed as being able to cut metal, only scribe and engrave. I suppose one could use it to make acrylic fan grills, using any design someone could make... Unfortunately, I don't think the wife would approve $8K for this project. Even if I could use it to make those laser scribed wood address boards you see people selling at craft shows.... Although, that might turn enough $$$ to make it worthwhile, they charge what, around $30-50 depending on the design you go with?
for cutting thin gauge metal in intricate patterns it might be cheeper to buy just a Jewler's Saw, which is basically a hand powered scroll saw. They allow incredibly thin cuts and tight curves and I've made many pendents and broaches in Copper, titanium, aluminum etc with one. They some blades and some wax can probably all be had for under $20
