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    Solid Bronze SBC chassis

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    • ?
      Guest
      last edited by

      Got my Jetway in the mail yesterday and I made a prototype case for it. One of my RJ45 jack openings is off a little. This is just the faceplate that needs fixing.
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      • ?
        Guest
        last edited by

        Here is an in progress check..

        open.jpg
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        • ?
          Guest
          last edited by

          Here is the stock heatsink that I am calling the bottom. I will add feet to it.

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          bottom.jpg

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          • ?
            Guest
            last edited by

            Here is the official chassis
            http://www.jetwaycomputer.com/JBC375F533.html

            Their chassis = 7.270 x 5.580 x 1.886 thick
            My Chassis    = 6.250 x 4.125 x 1" thick

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            • ?
              Guest
              last edited by

              The Jetway bios has an setting for Intel LAN Driver Health in the bios and I had never heard of it…

              UEFI Driver Health protocol.

              It is used for protecting device drivers.

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              • ?
                Guest
                last edited by

                Well done, nice case! +1 one from me for sharing this.

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                • ?
                  Guest
                  last edited by

                  Version 2 might include slots for 2 of these

                  http://www.amazon.com/ZIPPY-Flightmax-5000mAh-3S1P-20C/dp/B0072ADJ4K

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                  • W
                    whosmatt
                    last edited by

                    That's pretty.

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                    • ?
                      Guest
                      last edited by

                      I made the faceplate out of solid but got it too thin(.030"). I had to soft peen it back into shape after milling some.
                      We just got an Omax Water jet so version 2 will be from a cad drawing..
                      I like prototyping first then make a real one. I am planning on countersunk screws. The fasteners you see are temp.
                      The heigth between heatsink and broze was off by .060. My flat plate is only 1" and i need a pinch more for perfection. I had to notch the lid for a stubborn lip on the usb connector. I did not want to touch the board.

                      All in all a fun build. I used to ditch the stock heasinks and build thermals into my case and I said why fight it, design around it. I hate that it is annodized black aluminum on bronze, but I have no 1" aluminum plate laying around.

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                      • J
                        jwt Netgate
                        last edited by

                        Given the price for CA 954 Aluminum Bronze (a 1" x 12" x 6" piece costs $325.78 on speedymetals.com) and that you milled away most of that, it's a pretty, but very pricey piece.

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                        • ?
                          Guest
                          last edited by

                          Yea these are just "drops" from other jobs. We nest parts and end up with fringes. Sometimes there are bronze wars for the scrap but i get first dibs. You are correct to say I machined about 20lbs of material away. I do believe it could be run'ed over with a car!!

                          If i were to persue the idea I am thinking casting could make it affordable and you can get sharper corners, whereas I am limited to an endmill of 3/8 diameter that can do 1" deep pocket. I had to undercut the corners for the square board.(Absolute minimal clearance.)

                          I am going to have to thin the sidewalls some for SMA antenna mounting. Side pocket of sorts. I am still debating whether to add the VGA connector. Also i pocketed for the 2 front switches but might just leave a hole. I was originally going to make a small plunger for power.

                          I considered sandblasting it to a matte finish. That or make it modern with radius-ed corners and shine it up.

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                          • J
                            jwt Netgate
                            last edited by

                            @Phishfry:

                            Yea these are just "drops" from other jobs. We nest parts and end up with fringes. Sometimes there are bronze wars for the scrap but i get first dibs. You are correct to say I machined about 20lbs of material away. I do believe it could be run'ed over with a car!!

                            If i were to persue the idea I am thinking casting could make it affordable and you can get sharper corners, whereas I am limited to an endmill of 3/8 diameter that can do 1" deep pocket. I had to undercut the corners for the square board.(Absolute minimal clearance.)

                            I am going to have to thin the sidewalls some for SMA antenna mounting. Side pocket of sorts. I am still debating whether to add the VGA connector. Also i pocketed for the 2 front switches but might just leave a hole. I was originally going to make a small plunger for power.

                            I considered sandblasting it to a matte finish. That or make it modern with radius-ed corners and shine it up.

                            I think you should consider acid etching it.  Acid etched bronze is fantastic.

                            We've considered cast aluminum a couple times.  (It wouldn't be my first cast aluminum enclosure, just never here.)

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                            • ?
                              Guest
                              last edited by

                              That sounds like a good way to get a beastie image on it. I was considering making a relief mask and sandblasting some design or logo..
                              Muratic Acid and Peroxide looks easy enough.

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                              • ?
                                Guest
                                last edited by

                                Heck the metal came from right up the road from you in Dallas. Delta Centrifugal is who we use. We used to buy it per job now we started stocking it. It was much cheaper to buy a big chunk and profit$. We are using SAE660 bearing bronze as we do lots of big thrust washers and carrier bearings. The Omax waterjet shoots water and garnett at 60K psi and it is pretty unbelievable. We use it for simple jobs such as cork and rubber gaskets (was very time consuming) to pretty intricate parts.We made some large gears for our old railway were we tippled up some 4" Steel for a 12" Thick bull gear that was pretty impressive. We cross pinned it and welded the crosspins and it has an internal keyway..She pulls like a 500T load uphill. Saved our company alot of money.

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                                • ?
                                  Guest
                                  last edited by

                                  Got that bull gear story wrong some. Originally we were doing 4" plate x 3 plates for 12" overall but we did a test cut and 4" deep gear tooth profile was kerfed' too much so we scaled back to 3" Plate x 4 each for a good gear tooth profile. Was like 28" dia. Shaft was 8" You should see the pit for our oldest railway. It looks like a mechanical museum.

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                                  • J
                                    jwt Netgate
                                    last edited by

                                    I'm familiar with waterjets.  This is right up the road:  http://www.techshop.ws/austin_round_rock.html
                                    I'm a member.  They have a Flow Mach 2 Waterjet (2031b model, so 10' by 6' work envelope.)

                                    http://www.flowwaterjet.com/~/media/Images/waterjet/waterjet/product%20detail/mach-2/pop-ups/PopUp_Mach2_2031b.ashx?la=en

                                    I've made several things on it (including tooling for some of what we do in the build room here.)  Mostly sheet stock though.

                                    I'm … Let's say I'm "familiar" with CNC mills, too.  My son just built a 1m x 1m CNC router for his high school robotics club.  He's a very technical boy.

                                    A long, long time ago, I was LA City, State of California, ASME (B31.1/B31.3 pressure piping) and AWS (D.1, D17.1, but not D15.1 Railroad) certified as a welder, too.  But that was the 80s, before I got into computers.

                                    Back then I held a well driller's license in 4 states and carried both general electrician's and certified plumbers cards (licenses) in NV (CA, AZ and UT all grant reciprocity for both), too.

                                    (Obviously we do the laser etching on a CNC setup in-housse.)

                                    We do a fair mount of CAD, too.  This is a near-future product: http://imgur.com/Hznt5Ah

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                                    • ?
                                      Guest
                                      last edited by

                                      Obviously we do the laser etching on a CNC setup in-house

                                      I Was wondering about that. Do you have the case fabbed in the US? I am talking about the ADI line.

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                                      • J
                                        jwt Netgate
                                        last edited by

                                        Yes.

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                                        • ?
                                          Guest
                                          last edited by

                                          All the more reason to support them!!!

                                          We have a Haas Mini Mill and a small Haas Lathe. I am mainly big lathe(36"x40'L) guy and specialty work as well as nightshift supervisor. My boss is the Foreman but he does most all the CAE/CAD in Solidworks on dayshift. It is so expensive we only have one seat. We use BobCAD on the floor rackmount and I hated it the day they bought that software. They need to upgrade us to MasterCAM….

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                                          • ?
                                            Guest
                                            last edited by

                                            So do you bring your own material to the Austin TechShop and just pay for machine time??

                                            Our Omax machine has a  accounting system whereas it will tell you what the part cost based on labor, garnett and machine time. I was pretty impressed with that.

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