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Old 03-23-2009, 08:03 PM   #11
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Nicely done!

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Old 03-24-2009, 12:08 AM   #12
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looks good to me

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Old 03-24-2009, 01:55 AM   #13
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nice work man. thanks for the ideas.

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Old 03-24-2009, 01:58 AM   #14
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Very cool. You already picked up on the buna N temp problem and of course silicone would be the long term solution. Nice work cutting the slot. I think it's the hardest part.

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Old 03-24-2009, 02:44 AM   #15
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Any tips on cutting the slot? Is that something I could attempt with a rotary tool?

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Old 03-24-2009, 03:17 AM   #16
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awesomeness, jealous.

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Old 03-24-2009, 12:56 PM   #17
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I rough cut the slot on the table saw with a metal cutting blade; three lengthwise passes to make three parallel grooves stopping short of the 11" length. Then I made a beveled crosscut to define the ends. I cut the grooves last bit to the ends with a hacksaw.

A little light work with an angle grinder to cut away the burrs and smooth it a little. But be careful with the grinder, the copper is soft so you need a light touch. Then I hit it with a couple of mill files and finally some steel wool.

There are a few low spots and divots along the way, but cleaned up you really don;t notice them.

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