Lean and Green - modular dual PC scratch build

Taking a little longer than anticipated to do the feet, what a surprise. :)

Filing / Weren't the same as each other which I expected with them being complex-ish & only doing a partial template. / Clamped them both together & filed them to be the same or at least very similar. :)

Pretty nice I think after a few swipes of the drum sander on 240 grit.

Tried doing the small pieces the same way by clamping them but they are too small to do that so I first tried to grind them down on the disc sander, didn't seem a great idea so fixed up a massive vice which was wasting away in the back yard so I could file properly, I used a little of the grinded angle as a guide for what angle I needed to file at & then finished off on the disc sander, these small pieces were far more work than the bigger triangle pieces but all parts are now ready to fix together.

I then got my drum sander on the go in the drill press to make all visible edges a bit nicer, they still need more finishing but they are quite nice now, the smaller pieces mount upside down to how they are in the pictures.

I'll try to complete the feet tomorrow, careful bit of drilling, cut a few rods & it should be a pretty simple process, would have done it in this session but I was feeling wasted so called it a day. :D

Sound card came today. :)

Found another place which had the extra drum sanders in stock, a rocking horse specialist shop :) so I cancelled with the one I been waiting about 2 months for & bought from the new place, should have them soon hopefully.

Not sure if i am a fan of the feet yet, will have to wait see.

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Originally Posted by Stonerboy779

Not sure if i am a fan of the feet yet, will have to wait see.

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Here you get to see, they do still need some fine tuning on the finishing but they are functional now. :)

At a stage where I need to be extremely careful so I don't screw up the effort to cut the pieces so I made a new drill guide to support 6.5mm bits now because that's the needed size for the 1/4 inch aluminium rod so have a load of 6.5mm & 2.5mm guides for rods & tapping holes, also the square bar I use for this is 3/8 inch thick so 0.5mm too small so I made it up with about 5 layers of masking tape on both sides. :D

However drilling deep with a power drill is still too unpredictable with a 10mm thick guide, I'd guess maybe a 30mm guide is needed for deep straight drilling, I'll make one for further deep drilling later in the project but this went ok just about & got my rod pieces plugged in.

Plugged & slotted all pieces together & was flipping perfect, I was really happy & still am. :D

This one I have to explain in words because it was difficult & I couldn't be bothered messing with the camera, it was pickling my head & was getting late & I was wasted once again. :D

Then had to mount the underside front bevel pieces, I sat & stewed on how I should do them for quite some time & then just decided to make them join the bottom stand panel, I first placed masking tape along the line for where they should mount, drew rough lines for where not to drill, then dotted 6 marks to drill on the bottom panel, then came the tricky part, aligning it right & clamping it so I could do starter holes to finish off on the drill press into the bevel pieces, I used 2 stacks of 10mm aluminium to support the bevels & spent ages getting them aligned & clamped properly, then finished off on the drill press, then used my quality new dorma 3 stage taps (awesome BTW), countersunk the panel & installed, was perfect. :)

The stands bottom panel just slides into place nicely.

On with the pictures of the base & man am I glad this went ok, could have easily been a wreck with 1 faint wrong move, it was pretty intense doing this today so have no doubt doing all the rest of the fixings will be similar. :D

So yeah only screws for the base are on the front small pieces, was a nice challenge but it's back to scroll sawing next time, these feet will get further finishing done on them but they are totally functional now which I'm happy with.

you should bag up all your aluminum dust and scrap so I can turn it into a scrap yard and buy myself a new rig :eek:

stunning work as always :D

woah okay now I like them alot that looks great :D

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Originally Posted by Stonerboy779

woah okay now I like them alot that looks great :D

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You're eating your words now. ;) I was with you though. I wasn't sure I was going to like them until I saw the finished product. So nice!

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Originally Posted by d_stilgar

You're eating your words now. ;) I was with you though. I wasn't sure I was going to like them until I saw the finished product. So nice!

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Well I thought it was going to be fixed in place the way he had it stacked haha can't blame me for thinking it looked strange.

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Originally Posted by SXRguyinMA

you should bag up all your aluminum dust and scrap so I can turn it into a scrap yard and buy myself a new rig :eek:

stunning work as always :D

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Hehe :D Thanks Will, yeah I've been scooping up any scraps that aren't of any use & bunging them all into containers & when it gets to certain weights I'll sell them, did think of making my own metallic paints with the dust lol. :D

Any scraps I think might be useful though I keep a big selection of them in the corner of the room, more than enough to do a load of smaller projects by now, it's been building up since my first scratch build. :banana:

Quote:

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Originally Posted by Stonerboy779

woah okay now I like them alot that looks great :D

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:D Thanks mate, understand why you thought that now. :)

Quote:

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Originally Posted by d_stilgar

You're eating your words now. ;) I was with you though. I wasn't sure I was going to like them until I saw the finished product. So nice!

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Thanks mate, yeah gravity wouldn't let me show it dry fitted. :D

Quote:

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Originally Posted by Stonerboy779

Well I thought it was going to be fixed in place the way he had it stacked haha can't blame me for thinking it looked strange.

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:D:up:

Insane amount of work bud. Good job so far.

Nice, nice, nice!

Oh, and another nice ;)