Help: Making Project boxes

Sat Feb 27, 2010 2:53 am   

I need some project boxes and was hoping to get advice on how to make
them.

I ruled out metal because small PCBs will be the contents of the boxes
and for obvious reasons this will not work.

That leaves plastic and wood. Has anyone here ever had to make project
boxes? And if some I'd appreciate some pointers.

Thanks.

Darren Harris
Staten Island, New York.

Sat Feb 27, 2010 2:53 am   

On Fri, 26 Feb 2010 16:53:03 -0800 (PST), Searcher7
<Searcher7_at_mail.con2.com> wrote:


Why is that obvious? Tons of people put pcb's into metal boxes.

John

Sat Feb 27, 2010 2:53 am   

John Larkin wrote:


--
Tim Wescott
Control system and signal processing consulting
www.wescottdesign.com

Sat Feb 27, 2010 3:32 am   

On Feb 26, 8:45 pm, Tim Wescott <t...@seemywebsite.now> wrote:

Use more PCBs to make your boxes. Kinda like 'birds of a feather....'

Sat Feb 27, 2010 4:23 am   

On Fri, 26 Feb 2010 18:40:46 -0800 (PST), George Herold
<ggherold_at_gmail.com> wrote:


Horseradish.

John

Sat Feb 27, 2010 4:40 am   

On Feb 26, 8:14 pm, John Larkin
<jjlar...@highNOTlandTHIStechnologyPART.com> wrote:

Yeah metal is great! It shields, it conducts heat, it's strong...what
else could a man want?

George H.

Sat Feb 27, 2010 2:26 pm   

On Fri, 26 Feb 2010 16:53:03 -0800 (PST),
Searcher7 <Searcher7_at_mail.con2.com> wrote:


Sounds like you just need some standoffs, so the
bottom of the PCB doesn't touch the case. You can
lay out the PCB to have a pad at each corner with
a hole in it for a #6 machine screw (or whatever).
If you want the circuit to be isolated from the
case, then each pad should be isolated from the
circuit. Or, if you want the case to be grounded,
you connect one or more corner pads to ground. (I
usually lay out boards so the ground is
surrounding the central circuit area, where
possible, so this is easy.)

If the PCB is really small (ie lightweight), you
might be able to hang it between the connectors
that are mounted on the outside of the case. If
the connectors have ground tabs, you can make
little "posts" out of stiff (cut-off component
lead) wire that you solder to the PCB, then
install the PCB by soldering the posts to the
connector grounds.


I've used small plastic boxes as cases, but these
were one-offs using boxes I just happened to have.
Seems there aren't that many products that come in
useful plastic boxes anymore, so I haven't done
this in years. Maybe an old VHS case?

I've done plenty of cases from wood "back in the
day". This was more for major projects like audio
amps or benchtop equipment, with power supplies
and a moderate amount of circuitry inside, so
probably bigger than what you are looking for.

The basic approach I used was to make the case as
2 "C" units, sorta like the old metal "Bud" boxes.
The top C (top and sides of the case) would be
made out of wood that could be nicely finished.
The bottom C would consist of a bottom upon which
the circuit would be mounted, plus front and rear
panels for switches and connectors. These latter
could be made from sheet aluminum or thin
Masonite, etc.

The front and rear panels could be screwed to the
edges of the bottom board, or the bottom board
could have a groove to hold them in place...
usually with a matching groove on the top and
sides of the case. Then big screws could attach
the sides to the bottom, so the end result looked
like a typical piece of stereo gear.

Best regards,


Bob Masta

DAQARTA v5.00
Data AcQuisition And Real-Time Analysis
www.daqarta.com
Scope, Spectrum, Spectrogram, Sound Level Meter
Frequency Counter, FREE Signal Generator
Pitch Track, Pitch-to-MIDI
DaqMusic - FREE MUSIC, Forever!
(Some assembly required)
Science (and fun!) with your sound card!

Sat Feb 27, 2010 11:10 pm   

"Searcher7" <Searcher7_at_mail.con2.com> wrote in message
news:120f52f6-ce3b-42f2-9a3c-7a50028f35c1_at_15g2000yqa.googlegroups.com...

As others have said, metal is a good choice because of shielding, and it is
simple enough to use standoffs to isolate the board.

I have used plastic instrument cases available from Jameco for about $5-$15
that are well-made, rugged, and easy to make holes for controls, meters,
etc.

If you are really strapped for cash, and really want plastic, you might
find some plastic food containers that could be used for project boxes.
Otherwise, you can often find things at flea markets, hamfests, or even in
the trash that can be gutted and reused for projects.

And you can make boxes from plastic sheet material. You may have to use the
right kind of glue, or use mechanical means to assemble them. You can find
suitable material for free, such as old CD cases.

And for some projects, you can use PVC pipe, which is very durable and
easily glued.

Good luck,

Paul

Tue Mar 02, 2010 4:47 am   

On Feb 26, 10:23 pm, John Larkin
<jjlar...@highNOTlandTHIStechnologyPART.com> wrote:

Hee Hee... big Grin. And I thought my job was to entertain you.

Way before chicken wings the essential 'bar food' in Buffalo was/is
Beef-on-Weck. Which is slow cooked roast beef on a Kimmel wick roll
(Hard roll with salt and caraway seeds) that you slather with
horseradish. Notin' better for clearing out the sinuses in winter.

George H.

Tue Mar 02, 2010 4:43 pm   

On Fri, 26 Feb 2010 16:53:03 -0800 (PST), Searcher7
<Searcher7_at_mail.con2.com> wrote:


How to article for abs plastic from abs sheet:
http://talkingelectronics.com/projects/Boxes/BJones-BoxArticle.html

I use wood for the stuff where size and sealing aren't critical. I
have one of the cheap 10" Makita bench top table saws, it can't be
beat for small projects - high precision with minimal effort.

An old tungsten carbide blade will cut aluminum with no problems too -
a small vise to use as a bending brake, and you can make aluminum
boxes, panels, mounting hardware, etc. Whitney Jensen/Roper hand
punch is inexpensive and works well - plus the essential hand nibbler,
and minor sheet metal projects are a snap.

--

Tue Mar 02, 2010 10:22 pm   

I saw where other people had suggested you just use "offests'when usinig
metal boxes, and your question came to my mind this morning when I finished
off a box of cinnamon mints. Mybe this is a dopey idea,btmaybe not, so here
goes:

Many mints come isvery sturdy boxes;, some are metal and some are plastic;
the Walgreens cinnamon drops come in a really small tin that's roughly
1.5"X2.5" and roughly 5/8"high.

If you and/or friends/family like mints anyway, maybe some of the mint boxes
would suit your purpose...? Also, if you don't need anything that's super-
sturdy, there are plastic snap-boxes used for collectable/trading cards that
might work out for you? Another idea is to check your local taples and
Office Depot as well as Michael's or HobbyLobby or other craft shop nd see
what sizes of wpre-made wood boxes they have.

Also, maybe these sites will help you out:

http://electronicsusa.com/productsboxes.html

http://www.westnc.com/boxomni.html

http://www.all-spec.com/products/Storage_and_Handling|Containers|CON-06/?x=25
&i=1&f=p


Well, hopefully one of those gives you some ideas...

Wed Mar 03, 2010 1:24 am   

"Bleep" <bleep_at_bleep.in> wrote in message
news:deKdnQx2QZdSHBDWnZ2dnUVZ_rmdnZ2d_at_earthlink.com...

Another possibility is to use one of the new blue plastic electrical boxes.
I've seen them as cheap as 20 cents each. They are certainly rugged enough,
but rather ugly.

Paul

Fri Mar 05, 2010 7:26 am   

On Mar 2, 7:24 pm, "Paul E. Schoen" <p...@peschoen.com> wrote:

Thanks everyone. I'll have to decide which option to go with.

But first. Where do i get those "new blue plastic electrical boxes"?

Thanks.

Darren Harris
Staten Island, New York.

Fri Mar 05, 2010 9:48 pm   

Searcher7 wrote:

Gray and black are also common colors.
http://google.com/images?q=electrical-outlet-box

Sat Mar 06, 2010 9:59 am   

On 2010-02-27, Searcher7 <Searcher7_at_mail.con2.com> wrote:

I've used sheet-metal, wood, and plastic to fabricate project boxes.
basically whatever was on hand, also re-used existing vessels.
(jars, cans, cases etc...)

For metal boxes just include an insulating spacer between the circuit
and the case. wood, plastic, several layers of electricians tape,
or part of the PCB itself. it may be advantageous to have the box
connected the circuits internal ground node.

Pick a material which you are comfortable working with and can do work
of acceptable quality in.


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