rack mount equipment box help

Andrew P. Follett · Apr 17, 2005

I've builit an audio project (a stereo 16 X 8 matrix mixer for a band's in
ear monitor system). I need a source for some place that can make me a
metal enclosure(s) to fit in a standard "road case" (19" equpment rack).
Same place needs to be able to punch/drill out all the holes for the
knobs/jacks etc. It would seem simple to find such a place but I either end
up talking to businesses that make airconditioning duct work or beams for
bridges! Anyone had "boxes" made? Dallas, Tx area - if that helps.

Andy

martin griffith · Apr 17, 2005

On Sun, 17 Apr 2005 12:37:28 -0500, in sci.electronics.design "Andrew
P. Follett" <apfoll@comcast.net> wrote:

I've builit an audio project (a stereo 16 X 8 matrix mixer for a band's in
ear monitor system). I need a source for some place that can make me a
metal enclosure(s) to fit in a standard "road case" (19" equpment rack).
Same place needs to be able to punch/drill out all the holes for the
knobs/jacks etc. It would seem simple to find such a place but I either end
up talking to businesses that make airconditioning duct work or beams for
bridges! Anyone had "boxes" made? Dallas, Tx area - if that helps.

Andy

try here

http://www.frontpanelexpress.com/
and
http://www.emachineshop.com/download/

you can buy "standard" 19" boxes and put your own front/backs on

hope this is a bit of help

martin

After the first death, ther is no other.
(Dylan Thomas)

Luhan Monat · Apr 17, 2005

Andrew P. Follett wrote:

I've builit an audio project (a stereo 16 X 8 matrix mixer for a band's in
ear monitor system). I need a source for some place that can make me a
metal enclosure(s) to fit in a standard "road case" (19" equpment rack).
Same place needs to be able to punch/drill out all the holes for the
knobs/jacks etc. It would seem simple to find such a place but I either end
up talking to businesses that make airconditioning duct work or beams for
bridges! Anyone had "boxes" made? Dallas, Tx area - if that helps.

Andy

Yo Dude,

You learned how to make complex circuits like that but not how to drill
holes in a standard 19'' rack box? Buy a drill!

--
Luhan Monat (luhanis 'at' yahoo 'dot' com)
"The future is not what it used to be..."
http://members.cox.net/berniekm

John Fields · Apr 17, 2005

On Sun, 17 Apr 2005 12:37:28 -0500, "Andrew P. Follett"
<apfoll@comcast.net> wrote:

I've builit an audio project (a stereo 16 X 8 matrix mixer for a band's in
ear monitor system). I need a source for some place that can make me a
metal enclosure(s) to fit in a standard "road case" (19" equpment rack).
Same place needs to be able to punch/drill out all the holes for the
knobs/jacks etc. It would seem simple to find such a place but I either end
up talking to businesses that make airconditioning duct work or beams for
bridges! Anyone had "boxes" made? Dallas, Tx area - if that helps.

---
Look in the yellow pages under "Sheet Metal Work" or something like
that and then look for the ads that have 'Precision' or 'technical' or
'electronic' in them or mention aluminum or stainless steel or CNC
equipment. We have several here in Austin, so you ought to have a
bunch in Dallas!

--
John Fields
Professional Circuit Designer

Richard H. · Apr 17, 2005

Andrew P. Follett wrote:

I've builit an audio project (a stereo 16 X 8 matrix mixer for a band's in
ear monitor system). I need a source for some place that can make me a
metal enclosure(s) to fit in a standard "road case" (19" equpment rack).
Same place needs to be able to punch/drill out all the holes for the
knobs/jacks etc. It would seem simple to find such a place but I either end
up talking to businesses that make airconditioning duct work or beams for
bridges! Anyone had "boxes" made? Dallas, Tx area - if that helps.

Unless the quantity is large, you'll want to start with a stock box and
have a local shop cut it with a laser or water jet. Many are designed
to take a separate front panel insert, which you can source pre-cut from
a shop like Front Panel Express.

The trade rags like EE Times have ads for enclosure makers; some popular
ones are Bud and OKW, and the usual distributors offer many (but not
all) of their lines - see Digi-Key, Newark, Allied, etc. for a starter.

At 2-3 rack units and above (1.75" per RU) there are a lot of options
out there - look for "enclosure". At the 1RU size, the options are a
lot more limited for some reason. There are shops that will make cases
for you custom, but at ~$200 apiece for a short run; that's a lot of
money for something that should be a stock item. At this rate, it's
easy for the enclosure to be 50% of your bill of materials.

Something else to consider... buying a pre-fab unit with power supply
and fan may be a ton easier/faster/cheaper than rolling your own
solution. (It's not hard for the mechanical aspects to take as much
effort as the electronics.) Also, don't forget about safety (e.g., UL)
and FCC certs.

Here's a collection of links I've compiled over time...
http://www.okwenclosures.com/catalogue/metal/info_pages/mettec19info.htm
http://www.sescom.com/enclosures/rack_chassis.html
http://www.altronics.com.au/index.asp?area=prod&grp=220
(I like the H5035, a steel box with a nice beveled face.)
http://www.chassis-plans.com/custom/custom-showcase.html
http://www1.jaycar.com.au/productView.asp?ID=HB5120&CATID=5
http://www.lansing-enclosures.com/
http://www.web-tronics.com/1usteelchasw.html
http://www.jdr.com/interact/item.asp?itemno=GR-3120A
http://www.protocase.com/products/standard.asp
http://www.industrial-enclosures.com/html/19-inch-enclosures.html

Front Panel work:
http://www.frontpanelexpress.com/home/index.htm
http://www.polycraftinc.com/samples.htm

Server cases:
http://www.rackmountplus.com/list.asp?MENU_SEQ=10101&PAGE=3
http://www.servercase.com/

Good luck!
Richard

Luhan Monat · Apr 18, 2005

Andrew P. Follett wrote:

"Luhan Monat" <x@y.z> wrote in message
news:CYw8e.7344$EX4.5956@fed1read01...

Andrew P. Follett wrote:

I've builit an audio project (a stereo 16 X 8 matrix mixer for a band's

in

ear monitor system). I need a source for some place that can make me a
metal enclosure(s) to fit in a standard "road case" (19" equpment rack).
Same place needs to be able to punch/drill out all the holes for the
knobs/jacks etc. It would seem simple to find such a place but I either

end

up talking to businesses that make airconditioning duct work or beams

for

bridges! Anyone had "boxes" made? Dallas, Tx area - if that helps.

Andy

Yo Dude,

You learned how to make complex circuits like that but not how to drill
holes in a standard 19'' rack box? Buy a drill!

--
Luhan Monat (luhanis 'at' yahoo 'dot' com)
"The future is not what it used to be..."
http://members.cox.net/berniekm

Yes, I own a drill : ). This is something I want to mass produce in the
end. Each channel of his matirx mixer has a volume and a pan control for
each of 16 inputs. There are 8 "channels" to the box so 16 X 2 X 8 comes
out to a minumum of 256 holes plus 8 more for headphone/output jacks (and
that's just on the front!). Drilling that many holes accurately without
doing something dumb, like drilling a hole in my hand, just takes more
ambition and concentration than I have anymore. So, I want to leave the
more "dangerous" stuff to the guys with the computer controlled metal
working machines.

Andy

Ok, I'm with you on this one. I've done a lot of custom panels and such

but nothing like that. Good luck.

--
Luhan Monat (luhanis 'at' yahoo 'dot' com)
"The future is not what it used to be..."
http://members.cox.net/berniekm

Andrew P. Follett · Apr 18, 2005

"Luhan Monat" <x@y.z> wrote in message
news:CYw8e.7344$EX4.5956@fed1read01...

Andrew P. Follett wrote:
I've builit an audio project (a stereo 16 X 8 matrix mixer for a band's
in
ear monitor system). I need a source for some place that can make me a
metal enclosure(s) to fit in a standard "road case" (19" equpment rack).
Same place needs to be able to punch/drill out all the holes for the
knobs/jacks etc. It would seem simple to find such a place but I either
end
up talking to businesses that make airconditioning duct work or beams
for
bridges! Anyone had "boxes" made? Dallas, Tx area - if that helps.

Andy

Yo Dude,

You learned how to make complex circuits like that but not how to drill
holes in a standard 19'' rack box? Buy a drill!

--
Luhan Monat (luhanis 'at' yahoo 'dot' com)
"The future is not what it used to be..."
http://members.cox.net/berniekm

Yes, I own a drill : ). This is something I want to mass produce in the
end. Each channel of his matirx mixer has a volume and a pan control for
each of 16 inputs. There are 8 "channels" to the box so 16 X 2 X 8 comes
out to a minumum of 256 holes plus 8 more for headphone/output jacks (and
that's just on the front!). Drilling that many holes accurately without
doing something dumb, like drilling a hole in my hand, just takes more
ambition and concentration than I have anymore. So, I want to leave the
more "dangerous" stuff to the guys with the computer controlled metal
working machines.

Andy

Andrew P. Follett · Apr 18, 2005

"Richard H." <rh86@no.spam> wrote in message
news:y8y8e.373$Zi.60@fed1read04...

Andrew P. Follett wrote:
I've builit an audio project (a stereo 16 X 8 matrix mixer for a band's
in
ear monitor system). I need a source for some place that can make me a
metal enclosure(s) to fit in a standard "road case" (19" equpment rack).
Same place needs to be able to punch/drill out all the holes for the
knobs/jacks etc. It would seem simple to find such a place but I either
end
up talking to businesses that make airconditioning duct work or beams
for
bridges! Anyone had "boxes" made? Dallas, Tx area - if that helps.

Unless the quantity is large, you'll want to start with a stock box and
have a local shop cut it with a laser or water jet. Many are designed
to take a separate front panel insert, which you can source pre-cut from
a shop like Front Panel Express.

The trade rags like EE Times have ads for enclosure makers; some popular
ones are Bud and OKW, and the usual distributors offer many (but not
all) of their lines - see Digi-Key, Newark, Allied, etc. for a starter.

At 2-3 rack units and above (1.75" per RU) there are a lot of options
out there - look for "enclosure". At the 1RU size, the options are a
lot more limited for some reason. There are shops that will make cases
for you custom, but at ~$200 apiece for a short run; that's a lot of
money for something that should be a stock item. At this rate, it's
easy for the enclosure to be 50% of your bill of materials.

Something else to consider... buying a pre-fab unit with power supply
and fan may be a ton easier/faster/cheaper than rolling your own
solution. (It's not hard for the mechanical aspects to take as much
effort as the electronics.) Also, don't forget about safety (e.g., UL)
and FCC certs.

Here's a collection of links I've compiled over time...
http://www.okwenclosures.com/catalogue/metal/info_pages/mettec19info.htm
http://www.sescom.com/enclosures/rack_chassis.html
http://www.altronics.com.au/index.asp?area=prod&grp=220
(I like the H5035, a steel box with a nice beveled face.)
http://www.chassis-plans.com/custom/custom-showcase.html
http://www1.jaycar.com.au/productView.asp?ID=HB5120&CATID=5
http://www.lansing-enclosures.com/
http://www.web-tronics.com/1usteelchasw.html
http://www.jdr.com/interact/item.asp?itemno=GR-3120A
http://www.protocase.com/products/standard.asp
http://www.industrial-enclosures.com/html/19-inch-enclosures.html

Front Panel work:
http://www.frontpanelexpress.com/home/index.htm
http://www.polycraftinc.com/samples.htm

Server cases:
http://www.rackmountplus.com/list.asp?MENU_SEQ=10101&PAGE=3
http://www.servercase.com/

Good luck!
Richard

Thanks for the leads. My unit will take up 6 to 8 units so the box with the
separate front panel sounds like a good option.

Andy

Pooh Bear · Apr 18, 2005

"Andrew P. Follett" wrote:

Yes, I own a drill : ). This is something I want to mass produce in the
end.

In which case - lol - you'll want to design your own box for economy.

Each channel of his matirx mixer has a volume and a pan control for
each of 16 inputs. There are 8 "channels" to the box so 16 X 2 X 8 comes
out to a minumum of 256 holes plus 8 more for headphone/output jacks (and
that's just on the front!). Drilling that many holes accurately without
doing something dumb, like drilling a hole in my hand, just takes more
ambition and concentration than I have anymore.

Not if you do it right ! Pilot holes etc.... I've even successfully reworked
exisitng painted panels with nothing more than a quality drill and bits and the
knowledge of how to do so efectively.

So, I want to leave the
more "dangerous" stuff to the guys with the computer controlled metal
working machines.

That'll cost.

Graham

Michael Black · Apr 18, 2005

Pooh Bear (rabbitsfriendsandrelations@hotmail.com) writes:

"Andrew P. Follett" wrote:

Yes, I own a drill : ). This is something I want to mass produce in the
end.

In which case - lol - you'll want to design your own box for economy.

Each channel of his matirx mixer has a volume and a pan control for
each of 16 inputs. There are 8 "channels" to the box so 16 X 2 X 8 comes
out to a minumum of 256 holes plus 8 more for headphone/output jacks (and
that's just on the front!). Drilling that many holes accurately without
doing something dumb, like drilling a hole in my hand, just takes more
ambition and concentration than I have anymore.

Not if you do it right ! Pilot holes etc.... I've even successfully reworked
exisitng painted panels with nothing more than a quality drill and bits and the
knowledge of how to do so efectively.

Of course, a drill press helps too. It seems obvious, but the line about

drilling the hand makes it sound like that's not one of the available tools.

For a quarter century I've had an adaptor to put my electric drill in to
make it a drill press, albeit a limited one. But one of the hardware chains
here routinely puts a real drill press on sale for forty dollars (Canadian),
and even once for thirty. If I was actually drilling much these days I'd
grab one.

I suppose it also depends on the panel. 1/8 inch is standard, but I
wonder if thinner metal can be used nowadays since the equipment
behind the panels is so much lighter these days.

There must be local places that will do it, however.

Michael

Michael A. Terrell · Apr 18, 2005

Tim Shoppa wrote:

some popular ones are Bud and OKW, and
the usual distributors offer many (but not
all) of their lines - see Digi-Key, Newark, Allied, etc.

With Bud and Hammond, any of the catalog houses will be glad to take
your order for something they do not usually stock and have it shipped
from the factory. In some cases if it's not in their online catalog,
the only way to do it is over the phone.

Tim.

Bud used to offer a customizing service where they would punch holes
for an extra charge. I haven't dealt with them lately, but its worth
checking out.
--
Former professional electron wrangler.

Michael A. Terrell
Central Florida

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