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Old 02-18-2011, 09:34 AM   #21
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When I laid out my box I covered all the surfaces to be cut/drilled in masking tape. Then I measured everything and marked it with PENCIL (erasers are nice). I then positioned all the components and made sure I liked their arrangement, and once I was satisfied I went back and drew over the pencil marks with a permanent marker.

The computer printout is a good idea. I tried it for a min, but I ended up abandoning it out of frustration. It just took me too long, and I wanted to see how things actually would look, which is why I went with the tape. An added benefit of the tape is it provides an extra layer of protection for the paint if you aren't planning on repainting it.

I didn't notice if you mentioned it, but if you have a plastic box like me I highly recommend starting the holes with the point of a razor knife before drilling to prevent the bit from walking. If it's metal use a center punch (a finish nail will work in a pinch, but punches are cheap). That will save you some serious heartbreak.

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Old 02-18-2011, 01:25 PM   #22
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Are the heat sinks REALLY necessary?
Yes.
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Old 02-18-2011, 02:41 PM   #23
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Thanks guys. Very good points. Will be unable to work on the project for one full week so I will catch you up when I get back on it.

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Old 02-18-2011, 03:10 PM   #24
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One thing I learned when laying out my box: I originally wanted everything on the lid:



I found out it was a LOT easier to fit everything in the box by putting the electronics through the side. It is also less hassle with wires because you can have everything in place with the lid off.

As you can see, things get tight in there very, very quickly.



Just another option for ya

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Old 02-18-2011, 06:33 PM   #25
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As you can see, things get tight in there very, very quickly.
There is always a bigger box. I am an electrical contractor. More times than I care to remember, I have seen people try to put 10 lbs of $hit in a 1lb box. It is best to get all your components, lay them out roughly, measure, leave room for your fingers and then get your box.

**edit** just read this back and I mean no offense nostalgia. Your project looks very nice. You have some nice components in there. My point is you did this awesome build and sacrificed your original goal because the box was too small. My $0.02.
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Old 03-17-2011, 07:24 PM   #26
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Back on track. After vacation and catching back up at work (meaning I have been procrastinating due to fear of cutting the box!!!)

Heres the basic layout (I forgot the E-stop last time and the bottom view).


The bottom. Everything but the gray receptacle is upside down for measuring purposes.


And so the cutting begins...and ends... that didn't take long. Broke the set screw.


Luckily I had another one! Started cutting again. One down...three to go!






...and then the second set screw broke while I was replacing the cutting wheel for the 2nd hole!!

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Old 03-17-2011, 07:25 PM   #27
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Any ideas on what to secure the cutting wheel with that wont break every 2 minutes?

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Old 03-17-2011, 07:33 PM   #28
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Quote:
Originally Posted by nostalgia View Post
One thing I learned when laying out my box: I originally wanted everything on the lid:



I found out it was a LOT easier to fit everything in the box by putting the electronics through the side. It is also less hassle with wires because you can have everything in place with the lid off.

As you can see, things get tight in there very, very quickly.



Just another option for ya

-Joe

Where's your heat sinks??
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Old 03-17-2011, 07:39 PM   #29
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Underneath the SSRs. The fan blows directly across the heat sinks and vents out holes in the back. It works a treat.

Like this, but with the heat sinks turned 90 degrees so the air blows across the fins.



-Joe

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Old 03-17-2011, 07:45 PM   #30
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Ahhh, I see em now. Good idea. I'm pretty sure I will have to mount mine outside the box.

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