[sdiy] Type of aluminium for front panels.

[Dave Kendall]

Hi all.

For the record, I experimented with a 2mm thick, 1U-wide 6U-high panel, 
and wasn't too happy with its strength.
The socket cutouts were 8mm (for cliff jacks), and were in 
equally-spaced horizontal rows of three, with 3/4" vertical spacing. 
The socket rows extended about half of the way up the panel, the upper 
part housing five 16mm alpha pots and four miniature toggle switches. 
When testing it, Even with jacks, pots and switches mounted, a hard 
push permanently deformed the panel.
I'm not exactly known for being in the kryptonite-avoiding class, hence 
the search for a stronger arrangement.

Thanks for all your advice - I now have a plan, with 2mm thick, 60mm 
minimum width panels, one 4mm banana per 20mm horizontal, 3/4" vertical 
banana spacing, and an angle bracket along one side. It's very solid, 
and the density of sockets is good, whilst leaving enough room for 
clear labelling.

Might even get some of it ready for this year's UK synth DIY Cambridge 
bash, although that may be tempting fate....   ;-)

cheers,
Dave



On 14 Feb 2013, at 23:51, David Moylan wrote:

> I just had a 5U rack panel done by Front Panel Express in 3mm.  Felt 
> very bendy until I attached some standard hardware store aluminum L 
> via standoffs, which I'm using to mount circuit boards.  I have 2 
> rails, one top, one bottom each attached by 3 standoffs (one on each 
> side + one middle).  Really makes a world of difference.  Might be 
> tough to fit in the 6U x 60mm specified but worth a try.
>
> On 2/14/13 3:35 PM, David G Dixon wrote:
>> I use 0.1" 5052 aluminum for my 5U panels, and it's stiff as hell.
>>
>>
>>>> I think the problem is that with a rack width of unbraced
>>> aluminium,
>>>> when you use any normal force against it, even if it only
>>> flexes by a
>>>> millimeter or two, it 'feels'
>>>> disconcertingly flimsy. It isn't going to break or deform
>>> permanently,
>>>> but it feels shoddy.
>>>
>>> Also, if there are panel mounted controls that are also fixed
>>> to a PCB, the PCB is going to take that strain.
>>> With an L- or U-shaped panel, there's less stress on the board.
>>
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