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Tired of routing all of the 5.25-inch drive rails, I switched to fabricating the PSU(s) mounting plate:
I made a router pattern for 5.25-inch drive cage.
And routered out the .10-inch thick aluminum.
The round corners were filed square.
Another pattern was made for the two PSU mounting holes:
Here's the plate (it still needs to be trimmed to its final width):
Next up were the two internal mounting plates for triple 140mm case fans.
Another aluminum part requires another router template/jig. A 140mm fan was sacrificed for use as a router template:
3/4-inch aluminum flat bar was epoxied to the fan frame to keep it nice and square.
The fan housing was used as a guide to route out yet another full size jig. The jig was placed over a double layer of .10-inch aluminum sheet and routed out with a 1/2-inch flush/pattern router bit.
The finished cuts require zero cleanup (filing/sanding).
Next up are the bottom mounting plates.
Which requires fab'ing yet another router jig.
G]
The finished result:
Lastly here's a grainy video of me routing one of the 140mm holes:
Now that I know how wide the widest plate is, the PSU mounting plate was cut to width and mounting holes were drilled.
I'm really proud of how well this turned out.
Another plate requires yet another router jig.
Both plates were routed out of one big sheet because the big sheet is easier to clamp to the workbench.
A test fit:
Looks good. Those sections are coming together great!
truly nice work with the router. :)
Filed, sanded, scratched and test assembled the 5.25-inch drive rails to the PSUs mounting plate.
Next up are the 5.25-inch drive rails for the four bottom mounting plates.
These (unfortunately) required a ridiculous amount of time to complete.
The fan covers are the last of the aluminum parts (yippee!):
I used a 1/2-inch router bit and an old router template to cut the wiring and tubing slots.
Now I just need to (re-)prep everything for powder coating and send them all off to the painter's.
For a wood worker you do some very nice metal fabrication. ;) I really like how this is looking.
