[Amps] Workshop Danger

[Manfred Mornhinweg]

Like many homebrewers, I cut my panel holes with a jigsaw, and finish 
them with files. The advantage: Essentially any shape and size is 
possible. Disadvantage: It takes a bit of practice to get nice, clean, 
good-looking results.

It's a good idea to use panels of a reasonable thickness. There is just 
no point in making them as thick as an armor plate! For small boxes I 
use 1mm aluminium sheet, for bigger ones slightly thicker sheet, and 
only for the biggest boxes holding the heaviest sort of components I use 
3mm thick aluminium.

On the other hand, I have used the jigsaw+file method even in 8mm thick 
steel, when building machinery! That takes some patience, though, and 
might wear out one jigsaw blade per hole. But that's still cheaper than 
having the work done by others.

Shop safety is not to be taken lightly. It pays to think in advance what 
can go wrong, and prepare for it. For example, a jigsaw blade can 
shatter and fly away, and small metal chips will certainly fly around. 
So, eye protection is a good idea. I also use ear defenders, as I like 
listening to music and don't want to go deaf. And un-deburred metal 
edges can cut fingers... but that's pretty obvious! Come on, we are no 
kindergarten anymore! ;-)

Manfred

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