Author Topic: Aerodyne - 2012  (Read 15417 times)

slipperyskip

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Aerodyne - 2012
« on: August 07, 2014, 10:05:43 AM »

VIA VE-900 mini-ITX mainboard w/ attached picoPSU.



Standoffs screwed into small wooden blocks. This helps me position the board up or down by removing or adding material. The system's SSD will be mounted underneath the board. Once the proper height is set I can order the appropriate sized standoffs.



Frame for the I/O plate.





Seven pieces of wood come together to form this...





I like the curve on this sugar canister.











This is a separator/bracket I made for my "ribs". I'll need five or six more at least.


My very first video. New camera so I'm playing around.
https://www.youtube.com/watch?v=d5V6LJFPOMM




« Last Edit: March 01, 2015, 12:15:16 PM by slipperyskip »

slipperyskip

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Re: Aerodyne - 2012
« Reply #1 on: August 07, 2014, 10:07:07 AM »
Thanks everyone! Its good to be back in the saddle. :dremel:




Dry fitting for the camera.





Inspired by...




slipperyskip

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Re: Aerodyne - 2012
« Reply #2 on: August 07, 2014, 10:09:22 AM »

Not knowing what the dimensions of the "motherboard tray" should be I just start building on one corner and work my way out. Wherever the work stops will be my edge.



Finished adding material to framework.







Marked the five spots for the grilles' locator holes. Used a brad point drill bit to drill most of the way through the board.







Shaped the grilles' locator pegs to fit the holes.



The grille will always be a dry fitting. The locator holes/pegs are only meant to keep the grille
in its set position.



Square holes being made by first drilling pilot hole then carving out rough shape of square. Finished off with sandpaper wrapped around square rod.



Testing the square hole accuracy and fit.



slipperyskip

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Re: Aerodyne - 2012
« Reply #3 on: August 07, 2014, 10:11:03 AM »

Cut the birch plywood "base" to the dimensions that look right...to me.







The four square pegs are friction fit to just barely protrude above the surface. I can now sand the ends so they are as flat as possible. This will all become clearer later...hopefully.



Made up some end caps and glued them into place. These complete the enclosure structure and makes it very solid.






Final trimming of the grille. It's just about ready to be sent out for casting :hehe: Casting?

slipperyskip

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Re: Aerodyne - 2012
« Reply #4 on: August 07, 2014, 10:12:54 AM »

My four "pegs" attached to a piece of 6-ply 1/8" birch plywood.





Four small brass wood screws are countersunk and driven into the backs of the pegs.





A design I'm playing with. A subroutine is constantly running in the back of my head concerning a decorative element for this thing. Lots of others to try out.





slipperyskip

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Re: Aerodyne - 2012
« Reply #5 on: August 07, 2014, 10:14:40 AM »

A refresher on how I cut panels. A stationary fence used with a finger fence and razor saw. It takes about 45 minutes for each cut. The result is a very clean edged cut that promotes adhesion for the following veneer layer. Power saws rip up plywood along the edges and thus lose a significant percentage of adhesion surface where it is needed most. Did I just say thus? Damn. Watching too many shows on the BBC.





Identical panels. I mark the corners that are factory laser cut so they can be matched up later.



First course for the sides.



Second course creating a pocket for the USB ports. Ends are criss-crossed.



Need to figure out how to do better close ups on this new camera.



Same corner as above after third course and trimming.



Fourth side is different. It has to be thinner to accept various switches and plugs.



Gathered up my remaining mahogany. The higher quality stuff comes in thinner widths but these pieces are laser cut so matching edges is easy. An acceptable compromise IMO.


slipperyskip

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Re: Aerodyne - 2012
« Reply #6 on: August 07, 2014, 10:15:51 AM »

In order to accurately locate the holes for the other side of my grill I made these two templates from thin basswood.



The slots line up with the pegs and the template is keyed to the panel edge.



Since the panels are the exact same size I can easily transfer the data over.





Confirmed the locations by measuring and placing the grill to compare it to the marks. Cut square holes for this side vice the round holes for the other. This will make it easier for the child labor to assemble it. Yes...I said that.



Trim away the excess panel material.





Assemble.



Hey wait a minute. That's starting to look familiar.



slipperyskip

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Re: Aerodyne - 2012
« Reply #7 on: August 07, 2014, 10:16:26 AM »





slipperyskip

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Re: Aerodyne - 2012
« Reply #8 on: August 07, 2014, 10:18:07 AM »

Located and cut a small square hole in the top of the USB support cradle.







The cradle will be pinched in place by the cover plate when it is eventually glued in place. The cradle is to remain "free" in case the ports need to be replaced.



The holes align with the grilles' location peg. When inserted the peg keys the USB cradle in place.





Spent about two hours with some hobby files rounding over the edges of the grilles' supports/separators. Minor detail but it is a dramatic improvement in the appearance. Might not be so dramatic in a photo.



Still picking that scab. These are templates for cutting the aluminum for the DE. The idea is the inlayed aluminum would be raised above the mahogany surrounding surface instead of flush fit. Also toying with the idea of coloring the lower hemisphere in something bright like red. Maybe brass?

Still looking at other alternative designs while I'm waiting for the delivery of my stainless steel power push-button.


slipperyskip

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Re: Aerodyne - 2012
« Reply #9 on: August 07, 2014, 10:19:51 AM »

The I/O shield spans over a large portion of the case's width. Adjustments must be made. The idea of doing this step was a big breakthrough while designing this case in my head. I was stuck on trying to fit the mini-ITX board into one compartment or the other. Using the entire volume of the case interior meant eventually having to cut a notch. Note: The motherboard is mounted upside down (relative to this photo).



Most of the material is carved out using my razor knife.





Stainless steel power button that was originally intended to be a starter/horn button for a custom motorcycle.



Goodies from Crucial arrived. Continuing the theme of complete overkill, 8GB of DDR3 and a 256GB M4 SSD.
 


Brackets made from aluminum angle.



Wooden brackets for the aluminum brackets.





Something like this. I'm going to wait for the wiring phase to determine the exact location of the SSD.



slipperyskip

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Re: Aerodyne - 2012
« Reply #10 on: August 07, 2014, 10:22:09 AM »



























slipperyskip

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Re: Aerodyne - 2012
« Reply #11 on: August 07, 2014, 10:24:02 AM »

Draw, score, drill, rasp, sand, sand some more, frame, veneer, sand = 14 hours.














Interviewing some aluminum mesh...

slipperyskip

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Re: Aerodyne - 2012
« Reply #12 on: August 07, 2014, 10:26:41 AM »

Couldn't go thru the project without at least one clamp sculpture.



Before and after one application of teal oil.





Framed up the mesh and painted the interior except for glue-down surfaces and "working" surfaces.











slipperyskip

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Re: Aerodyne - 2012
« Reply #13 on: August 07, 2014, 10:27:33 AM »



slipperyskip

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Re: Aerodyne - 2012
« Reply #14 on: August 07, 2014, 10:29:03 AM »
Teaser photo...



Still got a ton of work to do.