Front panel material

[Theo]

Hi Terry,  see inline.

> From: "terry michaels" <104065.2340 at compuserve.com>
> Subject: Front panel material
>
>
> > Hello list members:
> >
> > I am planning to make some front panels similar in appearance to those
> used
> > in the Moog modular systems.  Basically, those panels are 0.063 inch
> > aluminum sheet, with the sides bent back to create a shallow U shape to
> > increase rigidity.  The panels are black anodized, and then lettering is
> > added by etching,

Not exactly, you can't etch paint. The lettering is done with a photo active
paint.
For DIY you can get precoated sheets from http://www.conrad.com (Germany),
there may be other sources around closer to where you live.

The material is brushed (one side fine , the other medium) not anodized,
this would be no problem since you seem to plan for black panels with white
lettering.

>>  although white silk screening is a possible alternative.
> > The question I have is, what alloy of aluminum was originally used, or
> > should used be used today?  6061-T6 is by far the must available alloy,
>> but  it doesn't appear to be what was used in Moog modules, a few of
which I
> > have here.

I don't know what alloy the above mentioned sheets are.
It is quite rigid, not 6061 for sure.

2mm 6061 is fine for panels,  although if you're looking for anodized sheets
you will probably end up with 1.5mm 5052 any way.

 >> 6061 is fairly soft, when you drill a hole in it, the back side
> > of the hole mushes out and always has a burr, and the drill bit tends to
> > clog.  I have a few scrap pieces of another, harder alloy, I'm guessing
it
> > might be 5005 or 5052 or something similar.  This alloy gives you a
clean
> > hole when drilled, the drill bit cuts small chips which don't clog the
bit
> > as easily.

You may want to try a sheet drill, this are CBN cut drills specially made to
work in thin materials.
Even with bigger diameters the hole stays round.
An other option are center drills, these are intended for making a center
hole for "rotating bench" work,
but work real well on sheet material too.
Both drill types reduce the burr and mushing effect,
however the drill speed (about 600 rpm for 10mm) and feed are more
important.
In general small ships are a bad sign, cause the breaking causes the drill
to vibrate the cut will be less clean.
(ok, we only talking front panels here, so vibration is not that important)
Also all drills work best when you work wet.

>> so, when you bend it, the outside of the bend develops tiny
> > longitudinal fractures, identical in appearance to the bends on the Moog
> > modules.  The same material seems to have been used in my Minimoog also.
> > Does anyone have any thoughts on this?

For brushed panels I use 2mm 6061 cause it's cheaper and more available.
1.5mm 6061 will work fine if you use U-shaped panels, I like the fact that
it doesn't fracture when bend.
So far I know most anodized material is 5052 or similar.

Just my 2cnt worth.
Bye, Theo

> >
> > Terry Michaels
>