working with waffled metal, like rectos --- plz read inside

[new_anuzzerone]

Hi,
sorry for my bad exaplanation. Take a look at the v-twin to get a clue.

I´m building a dr boogey at the moment and wanted to make a real cool enclosure for it. So I thought of a 1590BB and put some recto-metal-waffle-stuff in front.

How do I flatten the metal, to make to pots run smooth on top? Take look at the v-twin (footswitches) to get an idea. Obviously it´s just a hole, which is not drilled in complete....but.....how do I do this???

I hope there´s anyone out there, who could help me. Any drills I´ve found so far, are just to drill, not to mill / shape something.

tia
regards

[gght]

Looks like it was done with an end mill. Those are pricey, and only work well in a CNC machine or similar. You might try a Dremel and a small cutter or stone attachment taking small bits at a time.

[new_anuzzerone]

thx, it sounds like "takes some more time".....just as I expected

let´s see, whats available...

[RnFR]

that stuff is called diamond plate.

[fergus_nz]

I've used a dremel before, works ok.

If i wanted to get the circular recess look like the v2 I would use hole saws in a drill press, multiple sizes, each size overlaps the others, drilling just deep enough to get the right effect.

The smallest three would do it i'd say:


Or borrow an end mill bit from an engineer buddy and use that in a drill press.

[JOHNO]

I would think a spade bit in a drill press could quite easily get that job done.

[new_anuzzerone]

The spade bit was the thing, I´ve thought about first. But you got these "pins" on the outside --> as far as you drill, you will always go through the metall - before you even scratch the surface, coz of the sides.

Theres something called "Forstner bit" which is nearly the same, as a spade bit, but it seems, these are only available to work on wood or "in" wood. I´ve tried a stony bit, like the one shown in the pic. Too many scratches and they´re not centered, so the stone mills not a circle, it´s more an egg (so to say).

Even in a drill press it´s impossible to keep it centered (I´ve tried it...). *sigh*

anyway, thx for your postings

[new_anuzzerone]

I just found the right tool, but I´m not willing to pay for it

The thing, which does these kind of work is called COUNTERBORE or "Flachsenker" in german.
A friend of mine gave me a clue...as usual: ask the right person and you´re done.

Negative aspect: these things are f***** expensive. To drill a 20mm "hole", it´s about 50 Euros, and I´m not sure, if it fits a normal drill. btw. the moneys just to buy the tool, no drill included *sigh*

at this site, you can see, what it does - it´s the second picture.
http://www.boettner.de/main/index2.php?p=produkte

So, let´s see, what else I could use.....weekends coming closer...

thx to everybody

[new_anuzzerone]

Just finished...

The tools arrived (I found them on evilbay, paid about $20 for 2 of them).

I tried to re-house my Red Llama clone, I think it looks great - now the parts for the Dr.Boogey have been ordered.

Take a look at the pics. The first shows, what happens, if the diamond plate is not totally secured and fixed in position. You got to work very slowly (I actually used some oil to drill and set the drill to a minimum of speed).
The other pics show the 1590B enclosure, the diamond plate finished and the whole pedal, re-wired.
The plate on top is secured by the screws of the fs and the pots

What do you think?

(wrong forum? plz move it

Here we go:
I´d like to introduce to you my
"red-llama-clone-rectifier-type-of-thing-whatever"



The "scratches" are not made by the actual counterbore, but by some sanding-stone, I tried before.

as you can see, you´ll get a smooth plate, to install the pots with no hassle

the assembled pedal