Homebrew PCBs

Does anyone know of a good way to build/buy/scrounge/anything
enclosures for circuits?  I've started making my own boards, but I
hate to spend a lot of money on those plastic boxes from radio shack.
 Does anyone have any ideas for cheap enclosures?

I use extruded aluminum:

1.) Extruded hollow aluminum bar stock. I purchase it
in two dimensions: 

1" tall x 3" height with 1/16" thick walls 
2" tall X 5" height with 1/16" thick walls   

Most extruded aluminum stock is manufactured with 4
holes that run from end to end. These holes are ready
to be tapped for screws. Further, I purchase it in 6
foot and 8 foot sections. I cut it using a small band
saw and then polish it. The boxes look *really* good.
Also, I think the most I've paid is something around
$12.00 USD for an 8 foot section. This comes out to at
most a dollar a box when you add end plates and
screws. 

If you need it to be water proof or are going to use
it in a hostile environment, purchase engine gasket
sealent. High temperature works the best. 

Best regards


Marvin Dickens
Alpharetta, Georgia


>  Does anyone have any ideas for cheap enclosures?
> 
> 


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Oh, one other thing: If you take the time to polish
the box with polishing rouge, the resulting finish is
nothing short of stellar.   

Best regards


Marvin Dickens
Alpharetta, Georgia

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----- Original Message ----- 

From: "greenseller" <Jay@...>
To: <Homebrew_PCBs@yahoogroups.com>
Sent: Thursday, November 06, 2003 3:20 AM
Subject: [Homebrew_PCBs] Boxes for our PCBs?


> Does anyone know of a good way to build/buy/scrounge/anything
> enclosures for circuits?  I've started making my own boards, but I
> hate to spend a lot of money on those plastic boxes from radio shack.
>  Does anyone have any ideas for cheap enclosures?

Someone I know uses cardboard boxes. 8-)

Radio amateurs use things like Altoid mint and tuna tins and often make
their own by
soldering pieces of PCB material together. Tobacco tins used to be very
popular, but are hard to get these days.

Leon
--
Leon Heller, G1HSM
Email: aqzf13@...
http://www.geocities.com/leon_heller

Thrift stores and dumpsters.  Old modem enclosures can be nice.  My 
favorites are old external drive cases; you used to be able to find 
lots of these when schools where dumping their old macintosh hardware.
Anyway, there are a lot of "disposable" electronics out there that 
can be recycled for a project.  My basement is full of this cra... 
er, RESOURCE.

--- In Homebrew_PCBs@yahoogroups.com, "greenseller" <Jay@F...> wrote:
> Does anyone know of a good way to build/buy/scrounge/anything
> enclosures for circuits?  I've started making my own boards, but I
> hate to spend a lot of money on those plastic boxes from radio 
shack.
>  Does anyone have any ideas for cheap enclosures?

In a message dated 11/6/2003 9:45:06 AM Central Standard Time, 
wheedal@... writes:
a lot of "disposable" electronics out there that can be recycled for a 
project.  My basement is full of this cra...    er, RESOURCE.<<
And you are in NEW ENGLAND???


[Non-text portions of this message have been removed]

I have some drawings of a simple sheet metal brake, made with angle
iron and hinges. I made mine years ago. Tools needed (the not so
common ones) are an electric drill, a threading tap, and a grinder. If
interested, I can send drawings of it. The design came from an old ham
radio magazine, but I don't have the article. You can make boxes with
it out of aluminum.


Grant

--- In Homebrew_PCBs@yahoogroups.com, "greenseller" <Jay@F...> wrote:

> Does anyone know of a good way to build/buy/scrounge/anything
> enclosures for circuits?  I've started making my own boards, but I
> hate to spend a lot of money on those plastic boxes from radio shack.
>  Does anyone have any ideas for cheap enclosures?

--- In Homebrew_PCBs@yahoogroups.com, "greenseller" <Jay@F...> wrote:
> Does anyone know of a good way to build/buy/scrounge/anything
> enclosures for circuits?  I've started making my own boards, but I
> hate to spend a lot of money on those plastic boxes from radio 
shack.
>  Does anyone have any ideas for cheap enclosures?


There are lots of different sizes for different needs.

I have done some CNC stuff and used larger boxes 6x6 and 8x8 from 
electical supply houses less than $20.00 each, called a pull box.  
check home depot too.

for even larger boxes, call around to your local alarm companies.  I 
rescued a half dozen enclsoures, little windows in them and gads of 
stuffed boards and parts.  they hold on to them for a little while 
for spare parts, but then just trash them.

And, as was mentioned, go to the grocery store and walk the isles.  
you may find you develop a real taste for shortbread cookies if the 
tins are the size you need.  funny thing is you can get a neat case 
AND a great snack for less than digi-key wants for just a box.

other than that, yard sales.

Dave

Hello Grant...and all...
         Though some may complain that it's a bit off topic for the 
group, I for one would LOVE to see that Metal Brake design. I've seen 
others mention it on the web but never an actual scan. You could post 
it in the files area just long enough for those interested to grab it 
then remove it to appease the naysayers!  :)

 The Case side of any project seems to always be the "Archiles Heel". 
Yard sales, The Salvation Army Store, and similar charity stores 
always seem to be a good source. I once found a group of 6 sloped 
panel desktop cases that someone had built into some kind of intercom 
system. After removing all the guts I was left with six boxes that 
only had one hole on the top panel and three small holes in the back. 
Paid all of $2.95 each (compared to $18.95 each for the same box 
brand new! The six 9 volt A-C adapters were a BONUS.

Good luck in your hunting. Too bad yard sale season is over (Well 
here in Canada it is at least.)

Cheers ....Dean.


--- In Homebrew_PCBs@yahoogroups.com, "grantfair2001" 
<grant.fair@s...> wrote:
> I have some drawings of a simple sheet metal brake, made with angle
> iron and hinges. I made mine years ago. Tools needed (the not so
> common ones) are an electric drill, a threading tap, and a grinder. 
If
> interested, I can send drawings of it. The design came from an old 
ham
> radio magazine, but I don't have the article. You can make boxes 
with

> it out of aluminum.
> 
> 
> Grant
>

--- In Homebrew_PCBs@yahoogroups.com, JanRw
> a lot of "disposable" electronics out there that can be recycled 
for a 
> project.  My basement is full of this cra...    er, RESOURCE.<<
> And you are in NEW ENGLAND???

Ummmm...  No.  I'm in So. Idaho these days.  Why?  Do they collect 
junk back east too?  :')

I've also made small water tight enclosures out of PVC fittings a few 
times.  Not pretty, but if you're going to bury them anyway; who 
cares?

--- In Homebrew_PCBs@yahoogroups.com, "wheedal99" <wheedal@h...> 
wrote:
> I've also made small water tight enclosures out of PVC fittings a 
few 
> times.  Not pretty, but if you're going to bury them anyway; who 
> cares?


me too, but for larger boards, Home Depot has a plastic enclosure 
with screw on lid and O-ring seal.


Dave

greenseller wrote:
> Does anyone know of a good way to build/buy/scrounge/anything
> enclosures for circuits?  I've started making my own boards, but I
> hate to spend a lot of money on those plastic boxes from radio shack.
>  Does anyone have any ideas for cheap enclosures?
> 

http://electronicsusa.com/miniboxes.html

http://electronicsusa.com/miniboxphotos.html

   This is one of the cheaper places to buy, especially in 1000's 
quantity for the small box.

   Also for slope front, Radio Shack used to have a small (6" or so 
wide) metal box that was very simple for how good it looked. 
Rectangular bottom, two sides folded up from the same piece.  The sides 
extend a little forward of the bottom and a little to the rear, and 
folded up to make the slope front shape.  Top was one piece a bit wider 
than the sides, wrapped around the sides as support, then a little 
longer at front and back and had tabs (actually just corners cut out to 
not interfere with the sides that made the leading and trailing edges 
long tabs) that went in over the bottom.  It basically snapped together 
when you wrapped it around the sides with the tabs tucked in.  Then also 
had 4 screws on the bottom for feet that went through the bottom and the 
tabs for extra holding.  Relatively easy to copy for a home made slope 
front box.  Doing this you could make a large slope front box for a 
small fraction of the normal selling price if wanted.

   Also look around, there is someone from Japan with a site on how to 
bend sheet plastic into boxes, not that it's too hard to figure out really..

Alan

Aluminum boxes? Even better, I chuck a stub of a pencil with one of
those replacement erasers on it in a drill press. Then with the drill
on slow or medium speed, press it down in overlapping circles all over
the aluminum. Just press and up again, don't roll it around. Ends up
with a great brushed aluminum finish like on the cowl of the Spirit of
St Louis.

Spray coat it clear the instant you are done, or it turns grey
everywhere you touch it.

You can also make enclosures out of doublesided PCB. I made a small
metal detector, the body of the case was a PVC endcap and the
faceplate was a doublesided PCB chunk. I used the brushed circle trick
above, rubbed on some lettering and clearcoated. Looks beautiful and
very professional.

Practice your plastic welding skills! Build your own enclosures from
sheet plastic.

Or cast them. Expensive if you are only making one of something, but
great if you are going to do a dozen or a gross of something. I have a
list for that, too. ;')
http://groups.yahoo.com/group/nwpropmasters
http://www.polyphoto.com/nwpropmasters

Steve Greenfield

--- In Homebrew_PCBs@yahoogroups.com, mpdickens <md30022@y...> wrote:

> Oh, one other thing: If you take the time to polish
> the box with polishing rouge, the resulting finish is
> nothing short of stellar.   
> 
> Best regards
> 
> 
> Marvin Dickens
> Alpharetta, Georgia

Yeah! I've been collecting things from toy store closeouts and thrift
stores to be made into sci fi props and for test equipment enclosures.

Folding travel alarm clocks, handheld games (especially the ones that
fold up), clear plastic boxes that held perfume bottles, etc.

There are a lot of old modems around here right now. Good sturdy
aluminum cases, great to bolt power transistors to for heat sinking.
Seen some older rack mount 10baseT routers, picked one up for $1.00 at
a thrift store.

I see the 100meg Zip drives off and on in thrift stores, too.

Steve Greenfield

--- In Homebrew_PCBs@yahoogroups.com, "wheedal99" <wheedal@h...> wrote:

> Thrift stores and dumpsters.  Old modem enclosures can be nice.  My 
> favorites are old external drive cases; you used to be able to find 
> lots of these when schools where dumping their old macintosh hardware.
> Anyway, there are a lot of "disposable" electronics out there that 
> can be recycled for a project.  My basement is full of this cra... 
> er, RESOURCE.
> 
> --- In Homebrew_PCBs@yahoogroups.com, "greenseller" <Jay@F...> wrote:
> > Does anyone know of a good way to build/buy/scrounge/anything
> > enclosures for circuits?  I've started making my own boards, but I
> > hate to spend a lot of money on those plastic boxes from radio 
> shack.
> >  Does anyone have any ideas for cheap enclosures?

While I wouldn't like to see a long discussion of the merits of
cabinet punches, I -would- like to see this posted in Files and/or Links.

After all, the first step to PCB design is figuring out what it has to
fit into.

Steve, moderator but not of neutrons.

--- In Homebrew_PCBs@yahoogroups.com, "Dean Batute" <phix_it@y...> wrote:

> Hello Grant...and all...
>          Though some may complain that it's a bit off topic for the 
> group, I for one would LOVE to see that Metal Brake design. I've seen 
> others mention it on the web but never an actual scan. You could post 
> it in the files area just long enough for those interested to grab it 
> then remove it to appease the naysayers!  :)
> 
>  The Case side of any project seems to always be the "Archiles Heel". 
> Yard sales, The Salvation Army Store, and similar charity stores 
> always seem to be a good source. I once found a group of 6 sloped 
> panel desktop cases that someone had built into some kind of intercom 
> system. After removing all the guts I was left with six boxes that 
> only had one hole on the top panel and three small holes in the back. 
> Paid all of $2.95 each (compared to $18.95 each for the same box 
> brand new! The six 9 volt A-C adapters were a BONUS.
> 
> Good luck in your hunting. Too bad yard sale season is over (Well 
> here in Canada it is at least.)
> 
> Cheers ....Dean.
> 
> 
> --- In Homebrew_PCBs@yahoogroups.com, "grantfair2001" 
> <grant.fair@s...> wrote:
> > I have some drawings of a simple sheet metal brake, made with angle
> > iron and hinges. I made mine years ago. Tools needed (the not so
> > common ones) are an electric drill, a threading tap, and a grinder. 
> If
> > interested, I can send drawings of it. The design came from an old 
> ham
> > radio magazine, but I don't have the article. You can make boxes 
> with
> > it out of aluminum.
> > 
> > 
> > Grant
> >

Alan King wrote:
> greenseller wrote:
> 
>>Does anyone know of a good way to build/buy/scrounge/anything
>>enclosures for circuits?  I've started making my own boards, but I
>>hate to spend a lot of money on those plastic boxes from radio shack.
>> Does anyone have any ideas for cheap enclosures?

http://www.interq.or.jp/japan/se-inoue/e_acryl.htm

http://www.mini-lathe.com/Bending_fixture/bending_fixture.htm


   Hunted up the links I had for homemade plastic bending.  Combined 
with Grant's simple brake it would make a pretty decent setup.  You can 
do a reasonable job by hand without a brake for plastic, but with the 
handle on the brake for leverage and a protractor on the side to go by 
you can do things with a bit more ease and accuracy.

Alan

--- In Homebrew_PCBs@yahoogroups.com, Alan King <alan@n...> wrote:
> Alan King wrote:
> > greenseller wrote:
> > 
> >>Does anyone know of a good way to build/buy/scrounge/anything
> >>enclosures for circuits?  I've started making my own boards, but I
> >>hate to spend a lot of money on those plastic boxes from radio 
shack.
> >> Does anyone have any ideas for cheap enclosures?

I use old PC metal cases. As soon a a PC is upgraded at work the old 
case is thrown, along most of it's contents. I scrounge some of the 
PSU's and switches and leave then in place.

Usually the cases are metal 16 gauge steel with a steel or ali frame 
in side... all chop up nicely and work well with reamer, hacksaw and 
all the standard PC case screws and stand offs to create the perfect 
small RF shielded enclosures for free.

Dom