DIY rack enclosure extrusion

GroupDIY Audio Forum

Help Support GroupDIY Audio Forum:

This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.

blue_luke

Well-known member
Joined
Dec 13, 2008
Messages
192
Location
Montréal, Québec
Hello all! :)

I made a rather interesting encounter today but let me give you a few lines of Background...

I am 71, retired and still doing electronic, mostly audio and industrial design.
I am sometimes called for industrial electronic design as a consultant.
I am not at all in the process of starting a new business.
I hate making chassis and enclosures for my projects! :) But it need to be done, and done right.

Now the last line is the most important.... Beer with me :)

I am currently building a kind of preamp/mixer/matrix/headphones amp thingy.
It should be 2 U high.
Don't ask about this design, it is only made in 2 exemplaries for me and a recordist friend.

The point...

The f***** enclosure!!

Gnnnn! :(

If you go the cheap and "that will do" route, it's going to look ugly and messy.
If you want to have it look good and pro, it's going to be excrushciently expensive! (yes!)
There is no middle point!
And we all love to see our projects looking nice and pro after all the time and effort involved in designing/building a DIY piece of equipment, do we?

Soooooo, I went to a place that sells "aluminium". I wanted to buy some bars, plates, angles etc.... for this aforementioned project.
But the owner is much more into making exclusive design extrusions.
So I told him that I could not find what I needed and he ask me point blank what I was looking for.
I explained to him our common predicament and he suggested that he would be willing to invest in the cost of the die and a few hundred pound of aluminium to test the market provided I supply him with a proper design and handle the sales!
This is the kind of offer we can not pass! :)
But I will need some help.
I have a pretty good idea of what we need but I am terrible at CAD design. I am more old school and at ease with paper, rulers and lead pencil.... and pocket calculator!
I would need someone who is fluent with AutoCAD, or at least can supply drawings in DXF format. Maybe FreeCad, that I still can't master! :(
The gentleman knows his stuff when it comes to design a die, but we need to supply him with a good drawing.
I have a fairly good idea of an extrusion that can be used to build any size of chassis/enclosure, rack mount or desk top using this extrusion and simple flat piece of .065 thick aluminium plate covers and sides, but I need help with providing the final CAD drawings. It has to be AutoCad (DXF?) format.

Who's in?
The way I see it, the extrusion could be sold in small quantities of say minimum 1 meter (40") long or longer, Or I can add value service by cutting length to your spec if needed, everything is opened as the extrusions will be a standard 20 feet long. This is a standard in the field.
The cost of packaging and shipping will become a consideration, but we all want to be the stuff as affordable as possible and economically viable for the manufacturer.
By the way, prices will be quoted in CDN$ and only natural finish (raw surface) will be offered, at least as a starter.

Comments?
Ideas?
Suggestions?

Luc
 
Are you aware of modushop?

https://modushop.biz/site/

They make a range of sizes and shapes of enclosures based on a pair of side extrusions with steel panels for top and bottom and aluminium ones for the front and back. They are remarkably affordable.

Frank Rollen also supplies a range of enclosures using a similar system but I don't have his web site details to hand.

Cheers

Ian
 
The f***** enclosure!!

Comments?
Ideas?
Suggestions?
[The f***** enclosure!!] -- See comments and images below:

Here is an example of a mechanical rack-chassis design that I recently completed
here-at-home for a small audio company located in Upstate New York:

1727665601830.png

I also recently finished this panel design for an audio company located in Ontario, Canada:
1727665696159.png1727671293960.png

And.....I am putting in the finishing touches of this "electronic module design" for
a project by the previous respondent #2 who is in the UK and he had me work on
this for him:

1727665881469.png

I had designed this entire chassis using SolidWorks Premium:
1727666014404.png

1727666059689.png

This is the completed manufactured rack-chassis of the above shown 3D CAD-models and it sold for $20,000 when fully decked-out and sold in quantities of 600-chassis per year. For this project, I had designed BOTH the mechanical chassis AND all of the internal PCB's:
1727666209532.png

[I am 71, retired and still doing electronic, mostly audio and industrial design] -- I'm 75-years old, still working and have been designing and building audio electronic equipment since the mid-1970's.


[I am sometimes called for industrial electronic design as a consultant] -- I also work as a "Design Consultant" (my "active audio" days are now sadly behind me!!! -- Band "sound-man", recording engineer, roadie, PA and sound systems design, etc. --) and I am currently working as such on a "100% FULLY-REMOTE" basis with a large U.S. defense contractor designing test equipment for STINGER Missiles used to wipe out Hezbollah, ISIS and the Taliban!!! >> TALK ABOUT MAJOR -- FUN!!! -- <<

[I am not at all in the process of starting a new business] --
Neither am I.

[I hate making chassis and enclosures for my projects!] -- I >> ENJOY << designing chassis and enclosures and I still find doing so to be -- FUN!!! --

[But it need to be done, and done right] --
Is there any other way???

[I am currently building a kind of preamp/mixer/matrix/headphones amp thingy. It should be 2 U high] -- You know..... there are plenty of affordable 1U, 2U and 3U enclosures available!!!

[But I will need some help] -- >> HERE I AM!!! <<

[I have a pretty good idea of what we need but I am terrible at CAD design] --
I have both pretty good ideas (I hold a U.S. Patent for a "novel and unique" 2U rack-enclosure design) and I am not too shabby with creating 3D CAD-design (See above).


[I am more old school and at ease with paper, rulers and lead pencil.... and pocket calculator!] -- Been there, done that!!! I have spent years and years and years standing at a "drafting table" creating and drawing schematics, mechanical designs and even PCB layouts -- WAY BEFORE -- computers were introduced!!! I even still have some of my mechanical pencils.

[I would need someone who is fluent with AutoCAD, or at least can supply drawings in DXF format. Maybe FreeCad] -- Does it have to be AutoCAD? As is shown below, I use the SolidWorks Premium 3D Mechanical Design CAD-Modeling program here-at-home to create all of my rack-mount chassis and panel designs. And.....SolidWorks -- DOES -- output both an AutoCAD DXF and DWG format file.

[The gentleman knows his stuff when it comes to design a die, but we need to supply him with a good drawing] -- Can do!!! See the above examples..... Show me what you need, OK???

Will something like this do???.....

1727669550517.png

[I have a fairly good idea of an extrusion that can be used to build any size of chassis/enclosure, rack mount or desk top using this extrusion and simple flat piece of .065 thick aluminium plate covers and sides, but I need help with providing the final CAD drawings] -- It's typically -- 0.064" -- aluminum. Help is here with providing you with your final CAD drawings:

1727670007269.png

[It has to be AutoCad (DXF?) format] --
Can do!!! GOT IT!!!.....

[Who's in?] -- Count me IN!!!.....


/
 

Attachments

  • JBW-Designed -- Audio-Broadcast-Lighting-Video Chassis-Equipment-Panels-Systems.pdf
    4.8 MB
Last edited:
Hello all! :)

I made a rather interesting encounter today but let me give you a few lines of Background...

I am 71, retired and still doing electronic, mostly audio and industrial design.
I am sometimes called for industrial electronic design as a consultant.
I am not at all in the process of starting a new business.
I hate making chassis and enclosures for my projects! :) But it need to be done, and done right.

Now the last line is the most important.... Beer with me :)

I am currently building a kind of preamp/mixer/matrix/headphones amp thingy.
It should be 2 U high.
Don't ask about this design, it is only made in 2 exemplaries for me and a recordist friend.

The point...

The f***** enclosure!!

Gnnnn! :(

I have a pretty good idea of what we need.....Suggestions?

Luc
[I have a pretty good idea of what we need] -- How about these?.....

https://www.takachi-enclosure.com/cat/extruded_aluminium_enclosures

1727735996340.png

/
 
Back
Top