[sdiy] slider/fader slot cutting techniques

[Tom Arnold]

On Tue, Dec 09, 2008 at 01:30:09PM -0800, Paul Dickow wrote:
> Dear Synth DIYers
> I am revamping my MIDI controller into a new box. 2 of the pots are
> slider/fader.
> 
> I haven't yet cut slider-slot type holes in enclosures yet.
> Recommended tricks/rules of thumb? Best tool to use?
> I want to make as non-wonky of a slot as I can...try to avoid wobbly
> edge. etc. the first time around.

I'm doing this exact thing right now and it has caused me quite a bit of
heartburn just learning how to do it.

My solution was to buy a small mill.  Probably overkill for a one off...

I could find no other method to do the holes cutting DIY without drawing
lines and using a dremel and the like which is not fun I can tell you.
Using a larger metal cutting blade like in a chop saw doesn't work well as
it usually wont even start to fulling penetrate the metal due to the large
diameter of the blade.  Even using the mill I will have to sharpen the ends
by hand so they are square.

Oh, and the heartburn?  Well, if you buy a mill and look at tooling you will
notice there are end mills specifically for aluminum, then people will tell
you that carefull application of lubricant and slow feedrate can bypass the
need for special tooling.  Only half true.  Cutting narrow slots in thin
aluminum really does require that special made-for-aluminum endmill...

-- 
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