[sdiy] slider/fader slot cutting techniques

[Paul Dickow]

Thanks to everyone for the replies on this. It is SO appreciated.
I should have included the info that I've opted for an ABS enclosure
on this project. Ordinarily I would not, but as a computer peripheral
and non audio device I thought I could go plastic on this one. Any
ideas about whether this will be easier to work with?

For my software music work having those faders is critical, but I can
see that for my synth DIY hardware projects...I'll be sticking with
good old knobs for now!

Fortunately this controller is only 2 faders, so I only have to put
myself through this pain (heartburn) twice! It's a Doepfer Pocket
Electronic outfitted with 14 knobs, 2 sliders. I just wanted to move
the whole setup to a lower profile box with smaller parts...

P

On Tue, Dec 9, 2008 at 2:54 PM, Tom Arnold <xyzzy at sysabend.org> wrote:
> 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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-- 
Paul Dickow
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