Sheet Metal Enclosure - 1st Draft
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Re: Sheet Metal Enclosure - 1st Draft
First test with metal enclosure. You'll notice there isn't anything for the speaker, mic or 12Vdc input.
As of right now the only tools you'll need are pliers (or just your hands) to bend the metal and an M2 or M3 tap.
This is for using a local metal fabricator. On the right side of the image you'll see slices to relief the metal to make it easier for bending at home. Care must be taken to no overbend because the tabs can tear.
TU, 73' DE NT1K - JEFF
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Re: Sheet Metal Enclosure - 1st Draft
Hi Jeff,
Thank you for your efforts. The honest (no disrespect intended) feedback I have for the design is it is not "sexy" enough. I understand the sides folding concept you've implemented, but the end result is not pleasing, at least to me.
73,
Robert, WA2T
Thank you for your efforts. The honest (no disrespect intended) feedback I have for the design is it is not "sexy" enough. I understand the sides folding concept you've implemented, but the end result is not pleasing, at least to me.
73,
Robert, WA2T
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Re: Sheet Metal Enclosure - 1st Draft
I'm no metal worker, but how about this idea as we are already folding metal anyways (manually, not really suited for mechanized packaging) - all in one piece of sheet metal, with screws only on bottom:
A top with full-length left+back+right sides that also have a short (1cm?) inward brims on the bottom side.
The left+right flaps also feature these brims.
The front has the bottom attached.
Mounting process:
drill all necessary openings,
drill through-holes into the bottom, drill pre-tap holes into the brims,
bend all brims,
bend the back into position,
pre-bend left+right,
insert boards-stack into top,
fully bend left+right into position, fitting plugs through the holes,
fold down front, screw everything together with self-tapping screws from the bottom.
To hold the boards in place we might need to glue some plastic blocks to the left/right and/or front/back parts that fit snugly between boards and top/bottom.
Any thoughts from the metal-working faction on the feasability of such a design?
A top with full-length left+back+right sides that also have a short (1cm?) inward brims on the bottom side.
The left+right flaps also feature these brims.
The front has the bottom attached.
Mounting process:
drill all necessary openings,
drill through-holes into the bottom, drill pre-tap holes into the brims,
bend all brims,
bend the back into position,
pre-bend left+right,
insert boards-stack into top,
fully bend left+right into position, fitting plugs through the holes,
fold down front, screw everything together with self-tapping screws from the bottom.
To hold the boards in place we might need to glue some plastic blocks to the left/right and/or front/back parts that fit snugly between boards and top/bottom.
Any thoughts from the metal-working faction on the feasability of such a design?
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Re: Sheet Metal Enclosure - 1st Draft
Looking at the pictures on this thread I cannot help but think of cutting up a biscuit tin or some tin plate sheets and making an enclosure. Or perhaps fab one from FR4 PCB with those little qrpme corner clamps?NT1K wrote: ↑20 Jan 2022, 14:26At this moment in time, I can't do much until I have a built (tr)uSDX in hand. Not comfortable in releasing something that I'm not certain will work. Once I get a unit (I'm currently in a group buy where parts have been purchased), I'll be able to test various cases out.M1KTA wrote: ↑19 Jan 2022, 17:31Faraaz VK4JJ wrote: ↑09 Jan 2022, 12:30 Watching this thread with interest. It is a really neat idea and the fact that users will have a choice as to metal or plastic housing is great.
Once a design is finalised, I'll brave the Alibaba fab houses and see if I can get some quotes.
73
Dom
M1KTA
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Re: Sheet Metal Enclosure - 1st Draft
I like this ideal but as someone else said PC board would work and is easier to work with...This radio is a perfect candidate for metal ammo can go bag aka go can ...You can add along wire antenna, battery, and a small foldable solar panel...The dimensions would help and A pdf file to
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Re: Sheet Metal Enclosure - 1st Draft
My first thought is that a metal case would be good for RF isolation. My second thought is a concern that a metal case will detune the tuned toroid LC circuits that are nearly (or actually,) touching it. As much as we read that the magnetic fields of toroids are held entirely within the toroid, they actually aren't. Toroids noticeably interact with nearby metals. Has anyone done any proximity tests yet?
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Re: Sheet Metal Enclosure - 1st Draft
I'm not able to dedicate the time to manufacture and distribute cases in bulk. I also won't be making small batches because the price will be too high. I Just have many things going on.
However, I am going to put my designs out there so that it can either improved upon, manufactured in bulk or a combination. As I stated from the start, I'm not looking to make a profit from this.
Here is the final result of my design (still have to tweak some dimensions).
There will some things needed to be 3D printed. Like a retaining ring for the speaker and spacers for the PCBs & Case.
There were a couple people that didn't like the design. I feel that it's the best that can be done when you are considering cost, material and getting it to work with a product that is already in production. Some suggestions (that were mailed) basically implied to "mill" the enclosure from a piece of billet which would raise the cost so high that you could buy 3 or 4 (tr)uSDX units for the price of a case. Another suggestion of using extruded aluminum was also suggested but involves milling. This is a WYSIWYG type of project.
When I feel the project is completed, I'll post all the documentation and will let certain aliexpress manufacturers aware of the project and could use it as a base to make their project from
However, I am going to put my designs out there so that it can either improved upon, manufactured in bulk or a combination. As I stated from the start, I'm not looking to make a profit from this.
Here is the final result of my design (still have to tweak some dimensions).
There will some things needed to be 3D printed. Like a retaining ring for the speaker and spacers for the PCBs & Case.
There were a couple people that didn't like the design. I feel that it's the best that can be done when you are considering cost, material and getting it to work with a product that is already in production. Some suggestions (that were mailed) basically implied to "mill" the enclosure from a piece of billet which would raise the cost so high that you could buy 3 or 4 (tr)uSDX units for the price of a case. Another suggestion of using extruded aluminum was also suggested but involves milling. This is a WYSIWYG type of project.
When I feel the project is completed, I'll post all the documentation and will let certain aliexpress manufacturers aware of the project and could use it as a base to make their project from
TU, 73' DE NT1K - JEFF
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Re: Sheet Metal Enclosure - 1st Draft
Jeff. Very nice indeed. Especially if one does not have access to 3d printing.
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Re: Sheet Metal Enclosure - 1st Draft
This is great!
There always will be.
Great idea. Thanks for sharing!
Karl
EI9ITB / KB8SWH
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Re: Sheet Metal Enclosure - 1st Draft
Looks very good.
I shall certainly keep my eyes out and look to get one.
Thanks for your hard work.
I shall certainly keep my eyes out and look to get one.
Thanks for your hard work.
G8 SNR
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Re: Sheet Metal Enclosure - 1st Draft
Have you run the same rig in both the plastic case and a metal one? I would expect the metal to provide better "shielding" from environmental rf and other electrical/magnetic stuff. Was there any noticable difference in the performance? Just wondering, thanks & 73
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Re: Sheet Metal Enclosure - 1st Draft
Jeff (NT1K),
Thank you for the really nice drawing file. Your diagrams are great. The final pictures look great too!
Do you have an equivalent DXF file that we could send to a metal fabricator like SendCutSend or OshCut?
Also, did you have your local metal fabricator paint the enclosure or did you do it yourself?
Thanks and 73,
Faisal VA3SFA
Thank you for the really nice drawing file. Your diagrams are great. The final pictures look great too!
Do you have an equivalent DXF file that we could send to a metal fabricator like SendCutSend or OshCut?
Also, did you have your local metal fabricator paint the enclosure or did you do it yourself?
Thanks and 73,
Faisal VA3SFA
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