> Contrary to what some people may say, you don't need a state of the art
> metal workshop. The only metal working tools I use are a jigsaw, a file
> or two and a drill. You > can make decent cabinets and chassis like
> this with just sheet aluminum, angle and a big bos of self tapping screws.
When I worked as a post-grad student for RKO Radio in Chicago, we produced a
number of highly professional projects using nothing more than the tools
David described. For chassis and panel work, once the opening is roughly
the size wanted, a file is used to carefully bring the rest of the opening
within specifications. After completion, our work was sent out for
anodizing, and engraving with white-filled letters.
I still use this method today. A small jigsaw is mounted upside down into a
large vise to easily move the metal work around. I am sure an OSHA (the
occupational safety administration in the U.S.) inspector would have a few
things to say, but the combination is locked down tight. I suppose it's
possible for the saw to become disengaged while operating in the vise, but
with the right orientation of the vise handle, that risk is pretty much
minimized.
Here's a recent example of a project that I sent out for engraving and
anodizing. Scroll down to the balanced antenna tuner cabinet:
http://www.qrz.com/db/w9ac
Paul, W9AC
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