Got sick of paying for rack mount chassis'

[dirkwright]

initially I bought it inspired by Dave P's metal work while realizing I had no way of making nice looking sectioned off shielding. Where that is a problem I could stick some EMI tape over it.. that may not fix it all but I would imagine it does something good. 

http://www.ebay.com/itm/60mm-x-30m-RF-EMI-EMR-Shielding-Copper-Foil-Tape-Ahesive-Conductive-/350629965385?_trksid=p3284.m263&_trkparms=algo%3DSIC%26its%3DI%26itu%3DUCI%252BIA%252BUA%252BFICS%252BUFI%26otn%3D21%26pmod%3D350629965364%26ps%3D54

I'll post pictures as I move along here

cost so far is 175 USD for the spot welder and 60 USD for the break

so about 240 with tax

I guess I'll try steel

Why not use mu metal self stick foil also?
http://www.ebay.com/sch/i.html?_trksid=p2050601.m570.l1313.TR2.TRC0.A0.Xmu+metal+foil&_nkw=mu+metal+foil&_sacat=0&_from=R40

 

[dirkwright]

front, back, top & bottom seems easy to make with the proper tools;
but the rack sides? they are pretty damn complicated m8, since they keep the whole unit "togheter" with a bunch of screws;
Anyway, this isn't impossible after all 
I'll follow your progress!

He also needs a much thicker front panel to support it in the rack.

 

[dirkwright]

now I need to figure out a good plan. I figure I can fab a chassis in a few hours at the cost of sheet metal but what makes the most sense as a design? What is the best way to cut the sheet metal for cheap that leaves a clean edge?

I don't think there are many answers; a guillotine does exactly it. You may want to use a scrollsaw or even a jigsaw but you would have to do a lot of filing and deburring.

What metals are the best to use?

You don't have much choice. Aluminium has the major advantage of being easy to work, particularly if you want to do rectangualr cutouts, but OTOH, you can't really rely on taps in aluminium. You have to use threaded inserts. Steel is used in the majority of cases, but must be passivated/protected. Most industrial manufacturers use pre-plated steel. Copper is an expensive option, does not need passivation, can be threaded.

In America we call that a sheet metal shear. Many different kinds available.

For inserts, there are Pem Nuts: http://www.pemnet.com/fastening_products/pem-self-clinching-fastener_new.html
and you need a press to put them in.

 

[dirkwright]

okay so,

so far working with sheet metal sucks. engles is spot on when he says "with the right tools." I'm not unhappy with where I am (even though it looks a bit sloppy) because I've used maybe 8USD worth of materials and I have a rack mount enclosure. The best solution for me might be to have the metal cut to size and then I can bend it and spot weld it together. The place I went to wanted $150usd (on top of the $60 for the sheet) to cut the 10 x 4ft sheet down. I bet I can source a place that will cut it for cheaper and I bet I can work with slightly lighter sheet metal. 20 gauge seems to be a bit too thick. I'm really curious how much copper sheet metal would cost. wouldnt it be great if I could make 2u enclosures available to you guys for about 35-40usd each? I could leave off the front panel and make it for even cheaper while just leaving a few bolt holes.

thoughts and ideas are appreciated.

Now you know why good boxes cost as much as they do. To do it very well requires expensive tooling. I like Woodward Fab for quality tools at reasonable prices: http://www.woodwardfab.com/