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Step 5The Chassis
The chassis was originally a flat sheet of steel, which I reclaimed from a defunct VCR. Check out that snazzy "high voltage" symbol stamped into the metal...
The steel was trimmed to size with a Dremel fitted with a cutting wheel. The sheet was then held in between the clamping sides of a "Workbench," and bent downward to a 90 degree angle, with a heavy steel carpenters square. This lent a decently uniform bend to the sheet, and there were few imperfections.
Most of the bend was done by hand (and body weight.) The bend was finished and the angle sharpened by pounding the top of the forming carpenters square (layed atop the sheet steel) with a rubber mallet.
Afterwards the formed chassis was cut to width, also with the Dremel.
Cutting the chassis holes
The large rectangular cutout for the transformer was made with a nibbling tool. They are very handy tools. The power tube socket holes (1in.) were too large for any bit, and were also "nibbled," and then filed down to reduce any sharp burrs or edges.
The rest of the holes were made with a stepped bit. This is a fantastic drill bit!!!! A single bit can drill holes from 1/4 to 3/4 in., and FAST, too! The $15 spent here was well worth it...
A pilot hole is needed for the stepped bit, so don't throw out the normal bits. They do made a smaller stepped bit, which I plan to get soon--then only the smallest pilot hole would be necessary.
Many pro and serious amateur builders use a die punch. A decent set runs $75 or more.
NOTE: When passing wiring in / out of the chassis, always protect the wires. Use rubber grommets in the holes to prevent any fraying or shorting.
The steel was trimmed to size with a Dremel fitted with a cutting wheel. The sheet was then held in between the clamping sides of a "Workbench," and bent downward to a 90 degree angle, with a heavy steel carpenters square. This lent a decently uniform bend to the sheet, and there were few imperfections.
Most of the bend was done by hand (and body weight.) The bend was finished and the angle sharpened by pounding the top of the forming carpenters square (layed atop the sheet steel) with a rubber mallet.
Afterwards the formed chassis was cut to width, also with the Dremel.
Cutting the chassis holes
The large rectangular cutout for the transformer was made with a nibbling tool. They are very handy tools. The power tube socket holes (1in.) were too large for any bit, and were also "nibbled," and then filed down to reduce any sharp burrs or edges.
The rest of the holes were made with a stepped bit. This is a fantastic drill bit!!!! A single bit can drill holes from 1/4 to 3/4 in., and FAST, too! The $15 spent here was well worth it...
A pilot hole is needed for the stepped bit, so don't throw out the normal bits. They do made a smaller stepped bit, which I plan to get soon--then only the smallest pilot hole would be necessary.
Many pro and serious amateur builders use a die punch. A decent set runs $75 or more.
NOTE: When passing wiring in / out of the chassis, always protect the wires. Use rubber grommets in the holes to prevent any fraying or shorting.
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