Enclosure for power supply

When there is a CNC machine and modern power tools, it is not so difficult to make a transparent case made of wood and plexiglas for the power unit (and other products). But how to get out of the situation, if there is no such equipment, and the desire to work with these materials is.Case for power supply
Below is described the process of making a homemade transparent case for the power supply using only simple and accessible tools. There are also many useful recommendations regarding the processing of Plexiglas. You will learn how to cut it, fit the parts to the size, drill holes in them, including rectangular ones. One of the simplest ways of connecting a tree and plexiglas is clearly shown. In addition, there is information about how you can still bond these materials to each other.

Tools and Materials

To make a self-made transparent case, you will need the followingmaterials:
  • transparent plexiglas about 5 mm thick;
  • wooden board or plywood not less than 10 mm thick;
  • countersunk head screws - 12 pieces;
  • small bolts with nuts - 4 pieces;
  • 250 V rectangular button and at least 2 A;
  • grit sandpaper P100 and P240;
  • mineral or synthetic motor oil;
  • assembled circuit board with mounting holes.
To get the finished product out of the above, you should prepare such tools and devices (especially in Yata only available and cheap):
  • electric drill;
  • wood drills with a diameter of 3 mm and 10 mm;
  • countersink;
  • hacksaw for wood;
  • clamp;
  • hacksaw for metal with blade;
  • Phillips screwdriver;
  • ruler;
  • black marker.
Housing for power supply
If you have an electric jigsaw, mill, screwdriver and grinder at your disposal, all this will significantly speed up the manufacturing process. However, it is quite easy to do without these rather expensive instruments. After all, one of the key tasks of the material is to showhow to make a transparent case using only budget tools.

Making wooden body walls

Let's start with the simplest operation, that is, with the manufacture of body parts from wood, that is, its end walls. For these purposes, you can take either wooden strips not less than 10 mm thick, or plywood of the same size. Even the remnants of any casing or trimming lining will do. It is not recommended to use chipboard or OSB, so these materials are not very suitable for the manufacture of small products. The dimensions of the parts in the presented example are 70x50x10 mm. Naturally, if you make a case for any of your product, then the width and height of the end walls is selected individually. Only the thickness of the wood should be left unchanged, since it will be difficult to make correct holes in thinner blanks by hand. Cutting such simple parts is cheaper with a regular wood saw. For a more accurate result, it is recommended to use a hammer and a saw. In fact, such small pieces can be made even with a hacksaw.Again, if you have an electric jigsaw - the task is only simplified. Much more important than cutting wooden blanks is fitting them. They must be absolutely identical and, at the same time, have the shape of a rectangular parallelepiped. Without a professional carpentry tool, this problem can be solved with just one clamp and emery paper with P100 grit. The abrasive is fixed on a flat surface, and the parts are joined to one another and ground until the edges are completely mated.

Making of the details of the case from plexiglass

Working with Plexiglas without any CNC machines is a bit more complicated than with wood. Although it is quite malleable, at first glance, the material, but if improperly processed, it constantly melts, bubbles, cracks and scratches. However, it is quite possible to cope with these difficulties by arming the information presented below. First of all, we determine the size of the parts. They are selected depending on the length and width of the end walls made of wood. First, any two opposite sides are made, then a pair of remaining ones.If anyone is interested, in the example the dimensions of the side walls are 140x70 mm, and the top and bottom - 140x50 mm. Now about the cutting of Plexiglas. The cheapest and most reliable way to cut this material is to use an ordinary hacksaw for metal. You can also cut using a special knife, homemade tools, engravers, electric jigsaws, milling cutters, etc. If, however, it is decided to use a metal hacksaw, then before performing the work, you need to master just a couple of tricks to avoid known problems . First, with such sawing, the plexiglass can melt due to friction. Secondly, the markup made by the marker can be difficult to wash away, especially if it is permanent. Thirdly, the plexiglass is very easily scratched, which considerably spoils the appearance of the finished product (as in the photos in the example). So, let's consider the methods for solving the above-described problems. To plexiglass does not melt when cutting a metal sheet, it must be pretreated with conventional engine oil. Moreover, you can lubricate both the canvas itself and the cutting line. If you apply oil on plexiglass, then it can be cut without problems even with electric jigsaw, and the material, while not melting. First,what comes to mind about washing a permanent marker is a common medical alcohol. Yes. He copes with the traces of the marker, but there is one trouble. The fact is that when alcohol gets on the edge of plexiglass, it gives noticeable cracks. To avoid such problems, it is better to use a normal marker for drawing markers. An even better option would be a nail that can easily scratch the cutting line on plexiglass. And the last moment. To protect the acrylic glass from accidental scratches, before cutting and processing it should be sealed with ordinary masking tape. In the example presented in the photo, this was not done, and the result can be clearly seen. Although all the work was done very carefully. Masking tape will not interfere with sawing, grinding or drilling, or assembly. Yes, and the problem with the traces of the marker disappears automatically. After cutting parts from plexiglass, they need to be adjusted in size. This can also be done on sandpaper, fixed on a flat base. At the same time, the material will also melt, but in this case it is better not to use oil.It is much more efficient to use ordinary water - it will cool the Plexiglas perfectly when grinding, preventing it from melting.
Case for power supply

A rectangular hole in Plexiglas

If everything is more or less clear with round holes, then without special tools, make a rectangular fit for this same circuit breaker is not easy. To solve this problem there are two ways. Both are simple. If there is the same electric jigsaw (or manual), then we simply drill small holes in the corners of the future nest, file a nail file into one of them, and work around the perimeter. Do not forget about lubrication. If there are no jigsaws, then we take an ordinary drill, the diameter of which is as close as possible to the width of the mounting socket on the body. We drill one or two holes, and then finalize it to a rectangular shape with the help of a usual cheap file.
Housing for power supply
Housing for power supply
In the latter case, the processing will be much faster and easier if the plexiglass is fixed in place beforehand.You should also first work with a file at an angle of 45 degrees on both sides of the workpiece, and only then align the face to a right angle.

Assembling the case from wood and plexiglas

When all the workpieces are done, it remains only to assemble them in one product. To begin with, let's analyze the options for attaching Plexiglas to a tree. The glue in this case does not quite fit, as its traces will be visible through the transparent material. Look, in the end, all this will not be very.
Case for the power supply
The simplest approach is with countersunk self-tapping screws. If they are distributed symmetrically, they will not spoil the appearance of the product. To assemble in this way, you need a drill, a drill with a diameter smaller than the hardware itself, and a countersink.
Case for power supply
Two adjacent blanks are mated and fixed together with a clamp. It is better to use two small ones, since the compression force plays a big role here. The fact is that when a drill goes through plexiglass into a tree with a weak fixation of parts, they necessarily shift, which is unacceptable. When the holes are ready, we make a seat under the head and screw in the screws.We do the same with all the walls of the hull.
Housing for power supply
Case for power supply
It is also worth noting that the use of screws is not always the best approach to solving such problems. Such a connection after several assemblies and fights will lose strength. Therefore, it should be used only in those cases if your device will not be opened frequently.
Housing for power supply
Housing for power supply
Case for power supply
If you need a transparent case with the possibility of endless disassembly, then instead of self-tapping screws, use special threaded bushings and countersunk head screws. In this case, the bushings are first screwed into the tree, and the screws are already screwed into them. Such a connection is absolutely not inferior to self-tapping screws in durability, but in terms of functionality it wins many times. After the trial assembly of the case, it remains only to integrate the stuffing into it.For fixing the printed circuit board in the bottom holes are made, and for its fixation bolts with nuts are used. If there are special radio-mounting racks with the corresponding threads, it is preferable to use them. The button shown in the example is fixed by itself. Additionally, we provide outlets for wires or holes for connectors, and assemble everything according to the scheme. If there is a desire, then we add rubber or plastic legs. As a result, we get an excellent transparent case for our crafts. Despite the rather fragile appearance, it is quite durable. In addition, the Plexiglas does not conduct current, because the case is safe from this point of view. If you do not like the presence of wood in the product, then instead you can use thick plexiglass. However, unlike a tree, it will have to be cut into threads for screws or bushings.

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