Bend it or Screw it

[low&slow]

Originally Posted by BR3W CITY

Thats a ton of words, for a complicated visual idea.

I'd run over to home depot and grab some 1/4" square tube in an 8ft stick for like $15. It cuts with a hack saw, and you can tac it together for a simple frame.

Build your skeleton, wrap it with metal...then find a natural point in which a seperation could be made. Cut the unit where it works, and put a couple of machine screw boss's on one side, and hold the two pieces together with some allen mechine screws for a clean look.

IMO thats the easiest way to get the form-factor you want, and can still cut into halves or pieces. I'd make sure to use super-thin AL since you'll have a skeleton to wrap it around...the same idea could be done with thicker AL also, but the you remove the skeleton and let the body stand on its own. Make any sense?

Yeah it was a lot to type. I was confusing myself typing it because I had a general idea in my head and I was trying to put it into words before I measured anything and before I even drew it out on paper.

As far as the tubing and such, I talked with a local machine shop today after I did a bunch of measurements and they said it will be $20 to cut the aluminum to the 2 sizes I need which will be 3 pieces. I also asked them about price for some 1in x 1in square tubing that measures out to 15 ft 8 in and they said after tax it will be $16.66. So all together it will be $36.66 which isn't too bad. I'll also save myself the extra $10 or so and cut the tubing myself, unless they throw in the cutting to size for free.

Now for screws, I like the way you think. I was thinking a long the same line as you with what types of screws to use. My first thought was to use the allen machine screws or even spanner machine screws. I'm actually trying to find a screw that looks similar to a pop rivet.

Also with the frame, I was planning on that being an essential part to where as once I have the frame in and the aluminum sheets screwed to it, I will be able to either take just the top off or one side or both of the sides for easier access to do all the wiring. Reason why I'd like access is because even though the wires will never be seen, I'd still like to keep them neat inside the box.