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  1. #1
    Join Date
    Aug 2010
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    Glenbrook NSW Australia
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    705

    Default Box up grade for the son

    The old cardboard box for the soldering station was on its last leg.
    Time to upgrade the CNC way, I let the pics tell the story.
    The son was very much surprised and please with the results.
    Still to put a handle on,Trying to work out the best fit?
    I was tempted to post this in the box making forum, but I think the howl of protest might have been to much.

    Russell

    Ps did try reversing the photo order 3 times and failed???
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    vapourforge.com

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  3. #2
    Join Date
    Feb 2004
    Location
    Oxley, Brisbane
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    79
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    3,041

    Default

    That is nice Russell.
    I bet it took a while to get all the bits worked out.
    I see that you used plywood for the material. Did you have any problems with splintering at all, because so far I have been spectacularly unsucessful with ply.
    Bob Willson
    The term 'grammar nazi' was invented to make people, who don't know their grammar, feel OK about being uneducated.

  4. #3
    Join Date
    Aug 2010
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    Glenbrook NSW Australia
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    Default

    Bob I know what you mean with the splintering.....I do not have a big problem with this job as I have had in the past where there were no narrow pieces as this is where i have problem with under 4mm wide or smaller across the surface grain usually lift the surface off.eg clock gearteeth...
    What I used was a 2mm x8mm endmilll with about 30 deg off vertical flutes at 18000 rpm feed rate of 750mm full deep cut. The ply was 6.35mm marine ply from Mr plywood
    Time line plus other info that went into the design;
    On and off over 2 days of thinking and redesign then about 2 hours to get all the gcode right,1 hour to cut it all out, As I made this out of scape pieces I ended up making 8 blanks so 8 change of stock. To cut this out in one go would have taken around 10 minutes, sanding with a strip flapper wheel to deburr the edge and light orbital surface sand all surfaces and glue the three section up (lid, body, draw) about 1 hour. Next day a outside sanding and first coat of urethane.
    While this dried I then cut out the brass catches for the front and made the pins to suit. Note these catches also hold the draw close as well as the lid .There lock into the lock position with solid click and do not fall open and there is a small pin that they rest on when open so as not to foul the draw when open.

    R
    vapourforge.com

  5. #4
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    Feb 2004
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    Oxley, Brisbane
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    Default

    Well that has given rise to another question. As you cut them on the flat, there would have been a small 1mm radius in each corner. How did you overcome that problem? Just overcut into each corner by 1mm?
    Bob Willson
    The term 'grammar nazi' was invented to make people, who don't know their grammar, feel OK about being uneducated.

  6. #5
    Join Date
    Nov 2008
    Location
    somewhere
    Posts
    152

    Default

    Hi Russell, nice work - looks like a very practical soldering station set up.

    I'm curious how you did the tabs as well, as I'm planning a similair tabbed box set up on a project.

    As well as bob's question on the overcut in the corners, did you manually create the tabs, or did you use a program to generate them for you?

  7. #6
    Join Date
    Aug 2010
    Location
    Glenbrook NSW Australia
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    Default

    Attached is the tab shape, on a 1mm grid, that I used for this project. You can have the keyhole effect totally on one side or end, But I went with 50/50.
    It ends up being a continuous pattern that your eye does not see it as being unusually, it just part of the effect.

    R
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  8. #7
    Join Date
    Aug 2010
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    Glenbrook NSW Australia
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    Default Recessed handle now fitted

    The son thought that a recessed handle would be good so that if something were to stack on top it would sit flat. so why not....
    All made from brass the handle is 6mm bar turned ends to a 3 mm pins The CNC the 2mm sheet arms to fit over and solder together and the supports are from 1.2mm sheet also CNC and then black epoxied in. The hinges pins are 3mm.
    The final coat of PU has been done just some protective wax for the brass and it all over.....
    R
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  9. #8
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    Default

    Now you're just showing off.

    It does look good though.

    Did you braze the joins?
    Bob Willson
    The term 'grammar nazi' was invented to make people, who don't know their grammar, feel OK about being uneducated.

  10. #9
    Join Date
    Aug 2010
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    Default

    The son ask the same question, No just solder but you can not see any silver.
    And yes I do like to show off .....when it all works out but there are times when

    R
    vapourforge.com

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