chuckworkb
Super Member
Now, that is cool.
Nixie tube clock 1950's cold war replica
Teti
Pioneer hoarder
Now I know what the inner and outer dimensions of enclosure are, I can do some metalwork.
Enclosure dimensions: 340 x 230 x 320 mm (WxHxD)
Front panel dimensions 350 x 240 x 4 mm (WxHxD)
Enclosure is fabricated from 20mm L shape aluminium profiles. 30 mm diagonal bracing.
Lazy cutting with reciprocal saw
Easy to achieve right angle with clamps
Finished sides with bracing. This adding stiffness to the enclosure when lifted by rack handles.
With hammond 7" rack hande
Bottom sheet 2mm thick aluminium. I was testing circle brushing, this will be brushed from inside in latter stage.
My amateur approach in cutting of rear aluminium panel
Drilling holes for rear panel. High accuracy of assembly is achieved in way, that I first drill holes in first part and attach to counterpart by clamps, then drilled holes in counterpart. You get really nice fit this way.
Assembled and all fits perfectly! getting there
Bottom side of enclosure. Rubber feet, time to take off protective film and drill holes for PCB spacers.
Holes for spacers drilled. All looks nice and shiny.
Enclosure dimensions: 340 x 230 x 320 mm (WxHxD)
Front panel dimensions 350 x 240 x 4 mm (WxHxD)
Enclosure is fabricated from 20mm L shape aluminium profiles. 30 mm diagonal bracing.
Lazy cutting with reciprocal saw
Easy to achieve right angle with clamps
Finished sides with bracing. This adding stiffness to the enclosure when lifted by rack handles.
With hammond 7" rack hande
Bottom sheet 2mm thick aluminium. I was testing circle brushing, this will be brushed from inside in latter stage.
My amateur approach in cutting of rear aluminium panel
Drilling holes for rear panel. High accuracy of assembly is achieved in way, that I first drill holes in first part and attach to counterpart by clamps, then drilled holes in counterpart. You get really nice fit this way.
Assembled and all fits perfectly! getting there
Bottom side of enclosure. Rubber feet, time to take off protective film and drill holes for PCB spacers.
Holes for spacers drilled. All looks nice and shiny.
Teti
Pioneer hoarder
Adding labels to the switches. Label is print out on laser printer, double side tape on bottom side, transparent tape on front side. This makes very easy to produce durable labels.
Adding wiring to the switches. Twisted pair made with cordless drill. White wire 0.1mm2
Installation of assembly modules inside the case. ready for front fascia and wiring.
Detail of rear panel with switchable and fused IEC socket still with protective film. Brushed finish.
Temporary front fascia with fixed tube assembly, easy to work with.1. I still haven't received the real deal at this point. 2. It would be shame to ruin an final piece.3.Changes to design are required
Detail of tube assembly.
Adding wiring to the switches. Twisted pair made with cordless drill. White wire 0.1mm2
Installation of assembly modules inside the case. ready for front fascia and wiring.
Detail of rear panel with switchable and fused IEC socket still with protective film. Brushed finish.
Temporary front fascia with fixed tube assembly, easy to work with.1. I still haven't received the real deal at this point. 2. It would be shame to ruin an final piece.3.Changes to design are required
Detail of tube assembly.
arts
Addicted Member
Teti-From the standpoint of concept,design and finally construction,you have demonstrated a level of skill and attention to detail rarely seen in the DIY world.
For a unit at this level of complexity,you have achieved a top-drawer level of fit and finish.I am really enjoying watching your efforts come together.Well done Sir!
Cheers,
Art
For a unit at this level of complexity,you have achieved a top-drawer level of fit and finish.I am really enjoying watching your efforts come together.Well done Sir!
Cheers,
Art
Teti
Pioneer hoarder
Thank you very much for your kind words Art
This is not my first project. check this out please: https://mniec.wordpress.com/2014/10...-power-amplifier-monoblocks-finished-at-last/
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Teti
Pioneer hoarder
Switches, push buttons and lights prewired and installed in temporary front panel.
All assembly modules installed, wires will be cut to length, terminated and tidy up. I don't have a crimping tool for 0.1" connectors, so I have to solder all wires separately. Quite time consuming.
All assembly modules installed, wires will be cut to length, terminated and tidy up. I don't have a crimping tool for 0.1" connectors, so I have to solder all wires separately. Quite time consuming.
Teti
Pioneer hoarder
First power on in the enclosure. IT'S ALIVE!, working but no time set or any other fuctions.
Detail of mother board and alarm board wiring. Time set and reset functions connectors are tied together for easier recognition.
Clock is working, last thing to do is wire selectors switches for alarm.
This was rather time consuming. Measure length of wires. strip them, twist, solder, bend a hook, solder to selector, strip the other side, solder connector etc.... at lot of flux!
Alarm switch selectors are prewired and terminated with 0.1" connectors. Input, minutes: 0-9 & 0-5, hours: 0-9 & 0-2. 4 Outputs outputs to the 74LS21N AND gate. Alarm clock set off if all 4 inputs are high.
Wiring input collectors from decade counter to one of the switches.
Detail of alarm selector wiring, please note BNC connectors for pulse input and output
Input connectors of alarm selectors are connected now cut and terminate outputs from selectors.
Terminating 0.1" inputs from alarm switch selector. I don't have a crimping tool, so I do it in old fashioned way and solder them.
Detail of mother board and alarm board wiring. Time set and reset functions connectors are tied together for easier recognition.
Clock is working, last thing to do is wire selectors switches for alarm.
This was rather time consuming. Measure length of wires. strip them, twist, solder, bend a hook, solder to selector, strip the other side, solder connector etc.... at lot of flux!
Alarm switch selectors are prewired and terminated with 0.1" connectors. Input, minutes: 0-9 & 0-5, hours: 0-9 & 0-2. 4 Outputs outputs to the 74LS21N AND gate. Alarm clock set off if all 4 inputs are high.
Wiring input collectors from decade counter to one of the switches.
Detail of alarm selector wiring, please note BNC connectors for pulse input and output
Input connectors of alarm selectors are connected now cut and terminate outputs from selectors.
Terminating 0.1" inputs from alarm switch selector. I don't have a crimping tool, so I do it in old fashioned way and solder them.
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Teti
Pioneer hoarder
All wires are connected, please note wires are no tidy as this is not a final form of wiring. Adjustment and cable management will be done once front panel in installed.
I have added 3" speaker in diagonal position to the rear bottom right corner. It's generating nice low rich tone.
Clock is working perfectly. NOS Bakelite chicken heads purchased from eBay. Please note writing on temporary front panel, made of hard board. This method is cheap and fool proof for prototyping when adjustments to design are needed.
I have added 3" speaker in diagonal position to the rear bottom right corner. It's generating nice low rich tone.
Clock is working perfectly. NOS Bakelite chicken heads purchased from eBay. Please note writing on temporary front panel, made of hard board. This method is cheap and fool proof for prototyping when adjustments to design are needed.
Teti
Pioneer hoarder
Finally panel from Schaefer AG arrived. I really have to praise their excellent service. Nice and safe packing with pack of sweets inside as a bonus ... well at least for people with sweet tooth like me
Panel itself is vacuumed with sticky foil on hard card board. Looks pro in my opinion.
Looks great. Grey powder coated panel with engraved lettering filled with jet black color. 350x250x4mm weights approx 1 kg. Very precise cuts no errors anywhere.
Also grey powder coating from rear side.
Aluminium panel in comparison with my state of the art hardboard panel
... well at least for people with sweet tooth like me
Panel itself is vacuumed with sticky foil on hard card board. Looks pro in my opinion.
Looks great. Grey powder coated panel with engraved lettering filled with jet black color. 350x250x4mm weights approx 1 kg. Very precise cuts no errors anywhere.
Also grey powder coating from rear side.
Aluminium panel in comparison with my state of the art hardboard panel
I LIKE MUSIC
Super Member
This continues to be one very, very cool, amazing and well done project!
Thank you for all of the pictures and the construction details.
Thank you for all of the pictures and the construction details.
Teti
Pioneer hoarder
This is progressing nicely.
I think I like your homemade panel better.......... Just kidding. They did a great job. Would it be rude to ask what it cost to have that made?
Not at all. Schaefer AG in Germany made it for me, 199 Euro including delivery to the UK. Leading time about a week and couple of days for delivery. Front Panel Express in the US www.frontpanelexpress.com/
Cost would be the same if panel was even bigger. Maybe I should have it half inch wider on sides, but this is not rack mount. dunno. too late now innit?
Teti
Pioneer hoarder
thank you I have published similar stuff on my blog mniec.wordpress.com
Teti
Pioneer hoarder
Making cover
But before front panel is installed, top cover must be manufactured. This is my amateurish attempt to make one, so please bare with me. Work is done on 805 x 325 x 1.2 mm aluminium sheet custom cut from eBay seller. panel cost £8.50 including delivery.
Accurate measurement is taken. Tailored by side of the enclosure. Line with sharp blade and marker pen is made.
Clamped, Line in 1/2 thickness of material depth is filed by small files. You can use exacto knife or saw blade. This should achieve nice right angle bend.
Then clamp between metal (Al) L profile and piece of wood, bent with help of wooden block to right angle. Aluminium is quite soft at filed line.
Adjusted by hand outside clamp
Thumbs up! I've done this first time in my life. It's easier than you think!
Fits perfectly.
Working on second right angle edge. Exactly the same process as first edge.
Nice top cover with perfect rign angle bend achieved at home.
Detail of bend edge
Fits snuggly.
Brushed finish inside the eclosure is achieved by strokes of steel brush.
Apply force with even, vertical strokes
Drilling holes for M5 screws to the side. Stainles steel flat head screws will hold cover in place
Finished top cover with bend edges and drilled holes for holding screws.
But before front panel is installed, top cover must be manufactured. This is my amateurish attempt to make one, so please bare with me. Work is done on 805 x 325 x 1.2 mm aluminium sheet custom cut from eBay seller. panel cost £8.50 including delivery.
Accurate measurement is taken. Tailored by side of the enclosure. Line with sharp blade and marker pen is made.
Clamped, Line in 1/2 thickness of material depth is filed by small files. You can use exacto knife or saw blade. This should achieve nice right angle bend.
Then clamp between metal (Al) L profile and piece of wood, bent with help of wooden block to right angle. Aluminium is quite soft at filed line.
Adjusted by hand outside clamp
Thumbs up! I've done this first time in my life. It's easier than you think!
Fits perfectly.
Working on second right angle edge. Exactly the same process as first edge.
Nice top cover with perfect rign angle bend achieved at home.
Detail of bend edge
Fits snuggly.
Brushed finish inside the eclosure is achieved by strokes of steel brush.
Apply force with even, vertical strokes
Drilling holes for M5 screws to the side. Stainles steel flat head screws will hold cover in place
Finished top cover with bend edges and drilled holes for holding screws.
Teti
Pioneer hoarder
Template for speaker grill holes / ventilation holes. Designed in the same program as front panel. Glued to surface by ordinary office paper glue to aluminium sheet and punched holes. It's crucial to punch holes in even, accurate position otherwise finish will look very unprofessional.
Drilled 2 mm holes, then stepping up by 1 mm drills up to 6 mm (1/4")
speaker grill holes / ventilation holes drilled and chamfered, protecting cover stripped off
Looks even better than I hoped for
Detailed picture of holes. This is going in a star pattern 360 degrees divided by 16 partitions.
Material is brushed inside, outside will be in black hammered paint finish. This have to be sanded and degreased prior to paint job.
Ready for paint job by Rust-Oleum Universal All-Surface Black Hammered Spray Paint - 400 ml. See those boxes of biscuits and Haribo bears? See! told ya I have a sweet tooth
Two coats of paint inside the cover
Four coats of Rust-Oleum Universal All-Surface Black Hammered Spray Paint on outer side. Let dry between coats and Final drying for 48 hours.
Drilled 2 mm holes, then stepping up by 1 mm drills up to 6 mm (1/4")
speaker grill holes / ventilation holes drilled and chamfered, protecting cover stripped off
Looks even better than I hoped for
Detailed picture of holes. This is going in a star pattern 360 degrees divided by 16 partitions.
Material is brushed inside, outside will be in black hammered paint finish. This have to be sanded and degreased prior to paint job.
Ready for paint job by Rust-Oleum Universal All-Surface Black Hammered Spray Paint - 400 ml. See those boxes of biscuits and Haribo bears? See! told ya I have a sweet tooth
Two coats of paint inside the cover
Four coats of Rust-Oleum Universal All-Surface Black Hammered Spray Paint on outer side. Let dry between coats and Final drying for 48 hours.
Not at all. Schaefer AG in Germany made it for me, 199 Euro including delivery to the UK. Leading time about a week and couple of days for delivery. Front Panel Express in the US www.frontpanelexpress.com/
Cost would be the same if panel was even bigger. Maybe I should have it half inch wider on sides, but this is not rack mount. dunno. too late now innit?
I will have to bookmark them for future reference.
Cover looks great.
