|Here is what your finished 89-cent chassis will look like.
- Richard Fisher, KI6SN
Founder, 73 Radio Row
|A 1/4-inch hole is drilled into the metal prior to making the cut-outs, shown in RED.
|Simple tools are all that are needed to sketch out the pattern.
|Etch the pencil pattern with an awl.
|Stress-reduction holes are drilled into the pattern before making the cut-outs with a hacksaw.
|Prior to folding the metal, here is what the completed pattern looks like.
|Held in a vise, the next step is to form the box following the lines you earlier sketched.
SEE FOOTNOTE BELOW
|The 1/4-inch wide folds along the edge form the bottom of the box. A small piece of wood was slid under the edge for support in preparation for drilling.
|Small machine screws hold the box together. Once they are in place, flip over the box and admire the great work you have done.
FOOTNOTE: In the vise, there are actually two bending edges. Again, they can be metal or wood. I used a piece of aluminum stock from the Home Depot that was cut in two with the hacksaw: http://thd.co/1QPxOYt They are much longer than the vise is wide. So for the smaller folds - indeed *all* of the folds if you'd like - the box is bent to the side of the vise. The metal "bend bars" are squeezed in the vise. Then the aluminum box is squeezed between the two bend bars - to the left or right of the vise. So your bends are not necessarily *in* the vise, but beside it. I used a couple of clamps on the outer end of the bend bars to keep things as tight there as they would be in the vise itself.