Step 6: Building the Bending Jig

This step is optional, but if you choose to do it you will have a curved front, to create the bend with the Snowflake I had to make a custom jig.

I used a pasta bowl, as I thought the shape was the most suitable for my needs, but you can choose any type you want - you could even bend the acrylic by hand, if you choose this method, then be warned - the acrylic will be hot.

The method
  1. Firstly I positioned the circle, that I had previously laser cut, in the centre of the bowl - this I did by eye.
  2. Next, use a permanent marker pen and draw a dot in the hole that is in the laser cut circle
  3. You then need to glue the circle to the bowl using hot glue - using the pen mark to centre it(You may use another glue, but I found that this was the easiest)
  4. Using the oven or similar, you then need to heat up the acrylic (I put it in at 100oC for 5 minutes, but I advise that you experiment with times/temperatures beforehand)
  5. While the acrylic is still hot, push it into the bowl, making sure that you use the circle to centre it properly - make sure you press down on the sides as to make them uniform
  6. Once it has cooled, remove it from the bowl
very nicely done ... looks very clean ... couldn't you use boiling water to soften the plastic to avoid smells from cooking it (maybe that's not a problem)
Yes, you could use boiling water to soften the plastic - it may even work better, as it might give more evenly distributed heating :D I used a oven that is well used and I didn't smell anything apart from the acrylic plastic.
Overall, this is a clever and well thought out design. However, I think the nuts and bolts showing on the front of the amp let down its generally clean lines. Given that they are like that to hold the case together, I'd suggest putting a false white front over these, held on with either supermagnets or double sided tape with a suitable hole for the volume control. You could leave a slight gap around the volume control and sandwich an LED between the front panel and the new front to give a glow around the volume control when the amp is on.
This is a good idea, but would a line of hot glue on the inside be sufficient? As it would require less laser cutting, but it would also mean that you couldn't take the amp housing apart as easily : / Thanks for the feedback, I will experiment with your idea and see how it comes out :)
Cool idea with the bowl for bending the acrylic!
Sansa + rockbox is the best.
I have a neat pack of Instructables to talk about, today on my Blog, and your's one of them! :) <br>http://faz-voce-mesmo.blogspot.pt/2012/11/instructables-traceparts-e-noticias.html
Awesome! Thanks for including it in your blog.
Beautiful design.

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