Metal Box

Background

Many years ago, I designed a Class B power amplifier based on Douglas Self’s “blameless” topology. But, I didn’t have a box to put it in. Now, I have access to tools to make a box. So, I decided to make one.

Methods

I only thought of doing this the day before Herestuck, so I did not have time to order materials. However, Dan gave me scrap 6061-T6 from the CBA Shop.

I designed the box in Onshape.

I cut the stock so that it can fit in the xTool (24" x 24") using the Famco Hydraulic Shear.

Then, I manufactured it in the xTool MetalFab (using full power and a speed of 50).

For my second attempt, I also sanded the back.

Finally, I bent the box into shape using the Finger Brake. The internet warned me about bending 6061: https://lt-aluminum.com/the-ultimate-secret-to-bending-6061-aluminum/. However, I tested beforehand (both with and against the grain), and found that there were no issues.

Assembly just used M3 nuts and bolts.

First Attempt

Second Attempt