Re: Cutting panels

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From	Joerg <invalid@invalid.invalid>
Newsgroups	sci.electronics.design, comp.arch.embedded
Subject	Re: Cutting panels
Date	Sun, 21 Jul 2013 09:32:40 -0700
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Cross-posted to 2 groups.

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amdx wrote:
> On 7/21/2013 4:47 AM, Don Y wrote:
>> Hi,
>>
>> I need to fabricate a "patch panel" for a network
>> distribution point.  Most COTS panels are fabricated
>> in multiples of 12 or 24.
>>
>> E.g., 1x12, 1x24 (as 12+12), 4x24, etc.
>>
>> Graphically, something like:
>>
>> 1x12 XXXXXXXXXXXX
>>
>> 1x24 XXXXXXXXXXXX XXXXXXXXXXXX
>>
>> 4x24 XXXXXXXXXXXX XXXXXXXXXXXX
>>       XXXXXXXXXXXX XXXXXXXXXXXX
>>       XXXXXXXXXXXX XXXXXXXXXXXX
>>       XXXXXXXXXXXX XXXXXXXXXXXX
>>
>> Each 'X' being an 8P8C RJ45S connector.
>>
>> Typically, these "connector assemblies" are fastened
>> to the rear of an aluminum plate while the connectors
>> themselves protrude through holes in that plate
>> (actually, since the connectors typically abut each other,
>> the holes are really long *slots*)
>>
>> [Sorry if all this is obvious -- if you've seen one such
>> panel, you'd understand what I mean]
>>
>> In my particular case (1-off), I need to fabricate two
>> "3x12" panels:
>>
>> XXXXXXXXXXXX
>> XXXXXXXXXXXX
>> XXXXXXXXXXXX
>>
>> My problem is cutting these long slots in some material
>> (e.g., aluminum) in a manner that doesn't look amateurish.
>> [I suspect these slots are punched in commercial offerings
>> so they are nice and square, etc.]
>>
>> You *know* aluminum with a file is going to look like
>> "aluminum with a file"  :< ...


Not sure why you'd see filed edges in this case. If you mean the
outsides of a cut panel I do this:

a. File with a coarse file, then a fine one.

b. Go over it with an electric sander and 240-grit paper or similar.

c. Go over it by hand with 600-grit paper.

d. If I want to be extra good I go over it once more with 600-grit and
chalk in it. Commercial product does not live up to that.


>>                         ...  I just can't imagine keeping
>> nice hard, straight edges going that route!
>>

A pint of Guinness can help with that :-)

> 
>  I'm don't know what type of connector will go in the slot, but many
> have a small lip to cover minor flaws. ...


IME they all have a lip. Else they'd fall out the back :-)


>                                   ... I if indeed the job is 3 long
> slots and not 36 small slots, I would fabricate it myself with a jigsaw
> and a file. I usually scribe lines in the aluminum and put a fresh coat
> of masking tape on the bottom of my jigsaw to protect the material, then
> grab the proper glasses, and lighting for good vision. ...


That's exactly how I do it. I use a Bosch 230V jig saw running a bit
slow on 120V, makes nice clean cuts. You just have to resist the
temptation of rushing the job by pushing too hard.


>                                                   ... I'd mount the
> aluminum securely maybe in a vise, maybe screwed to a piece of wood.


I clamp it to a wooden workbench. Also with some masking tape so the
clamps won't mar the aluminum.

-- 
Regards, Joerg

http://www.analogconsultants.com/

Thread

Cutting panels Don Y <this@isnotme.com> - 2013-07-21 02:47 -0700
  Re: Cutting panels John Fields <jfields@austininstruments.com> - 2013-07-21 08:05 -0500
    Re: Cutting panels Roberto Waltman <usenet@rwaltman.com> - 2013-07-21 10:38 -0400
      Re: Cutting panels "Carl Ijames" <carl.ijames@nonono.verizon.net> - 2013-07-21 12:36 -0400
        Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-21 09:48 -0700
          Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-21 13:29 -0700
            Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-21 14:10 -0700
              Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 16:23 -0700
          Re: Cutting panels Grant Edwards <invalid@invalid.invalid> - 2013-07-21 21:04 +0000
            Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-21 15:07 -0700
              Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-21 16:35 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-21 17:11 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 16:27 -0700
                Re: Cutting panels Robert Wessel <robertwessel2@yahoo.com> - 2013-07-23 21:50 -0500
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 21:24 -0700
                Re: Cutting panels Jasen Betts <jasen@xnet.co.nz> - 2013-07-24 09:09 +0000
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-24 16:02 -0700
          Re: Cutting panels hamilton <hamilton@nothere.com> - 2013-07-21 16:52 -0600
            Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-21 17:13 -0700
        Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-21 12:35 -0700
  Re: Cutting panels amdx <nojunk@knology.net> - 2013-07-21 09:54 -0500
    Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-21 09:32 -0700
      Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-21 13:36 -0700
        Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-21 14:04 -0700
    Re: Cutting panels [solved?] Don Y <this@isnotme.com> - 2013-07-21 13:14 -0700
      Re: Cutting panels [solved?] Don Y <this@isnotme.com> - 2013-07-21 13:26 -0700
        Re: Cutting panels [solved?] Joerg <invalid@invalid.invalid> - 2013-07-21 14:06 -0700
          Re: Cutting panels [solved?] Don Y <this@isnotme.com> - 2013-07-21 16:08 -0700
            Re: Cutting panels [solved?] Rich Webb <webb.ra@example.net> - 2013-07-21 19:42 -0400
              Re: Cutting panels [solved?] Don Y <this@isnotme.com> - 2013-07-23 21:45 -0700
            Re: Cutting panels [solved?] Jan Panteltje <pNaonStpealmtje@yahoo.com> - 2013-07-22 07:51 +0000
            Re: Cutting panels [solved?] Charlie E. <edmondson@ieee.org> - 2013-07-23 05:57 -0700
              Re: Cutting panels [solved?] Don Y <this@isnotme.com> - 2013-07-23 14:46 -0700
                Re: Cutting panels [solved?] Don Lancaster <don@tinaja.com> - 2013-07-23 16:41 -0700
                Re: Cutting panels [solved?] Charlie E. <edmondson@ieee.org> - 2013-07-23 17:21 -0700
                Re: Cutting panels [solved?] Jasen Betts <jasen@xnet.co.nz> - 2013-07-24 09:26 +0000
                Re: Cutting panels [solved?] Don Y <this@isnotme.com> - 2013-07-25 12:11 -0700
                Re: Cutting panels [solved?] Spehro Pefhany <speffSNIP@interlogDOTyou.knowwhat> - 2013-07-25 16:04 -0400
                Re: Cutting panels [solved?] Don Y <this@isnotme.com> - 2013-07-25 13:03 -0700
          Re: Cutting panels [solved?] Jasen Betts <jasen@xnet.co.nz> - 2013-07-23 13:40 +0000
            Re: Cutting panels [solved?] Joerg <invalid@invalid.invalid> - 2013-07-23 07:38 -0700
      Re: Cutting panels [solved?]/summary Don Y <this@isnotme.com> - 2013-07-29 15:18 -0700
  Re: Cutting panels andrews@sdf.lonestar.org - 2013-07-21 12:45 -0700
    Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-22 19:17 -0700
  Re: Cutting panels Spehro Pefhany <speffSNIP@interlogDOTyou.knowwhat> - 2013-07-21 19:45 -0400
    Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-21 17:07 -0700
  Re: Cutting panels Peter Bennett <peterbb@somewhere.invalid> - 2013-07-21 16:57 -0700
    Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-21 20:58 -0700
      Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-21 21:02 -0700
      Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-22 09:20 -0700
        Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-22 12:15 -0700
          Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-22 16:17 -0700
            Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-22 18:52 -0700
              Re: Cutting panels Jasen Betts <jasen@xnet.co.nz> - 2013-07-23 14:00 +0000
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 15:13 -0700
              Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-23 07:09 -0700
                Re: Cutting panels Charlie E. <edmondson@ieee.org> - 2013-07-23 10:03 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 21:59 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 15:54 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-24 13:09 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-24 15:51 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-26 09:13 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-26 11:35 -0700
                Re: Cutting panels Paul Rubin <no.email@nospam.invalid> - 2013-07-26 12:06 -0700
                Re: Cutting panels Jan Panteltje <panteltje@yahoo.com> - 2013-07-26 19:44 +0000
                Re: Cutting panels Paul Rubin <no.email@nospam.invalid> - 2013-07-26 22:21 -0700
                Re: Cutting panels Jan Panteltje <pNaonStpealmtje@yahoo.com> - 2013-07-27 08:12 +0000
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-26 13:42 -0700
                Re: Cutting panels Paul Rubin <no.email@nospam.invalid> - 2013-07-26 18:50 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-26 22:49 -0700
                Re: Cutting panels Paul Rubin <no.email@nospam.invalid> - 2013-07-27 00:53 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-27 10:16 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-26 23:52 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-27 17:36 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-28 09:22 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-28 12:31 -0700
                Re: Cutting panels Paul Rubin <no.email@nospam.invalid> - 2013-07-28 13:48 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-28 14:20 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-28 16:35 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-28 17:39 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-28 19:38 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-29 11:15 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-29 16:30 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-29 17:38 -0700
                Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-29 21:45 -0700
                Re: Cutting panels Joerg <invalid@invalid.invalid> - 2013-07-30 12:20 -0700
  Re: Cutting panels Jeff Liebermann <jeffl@cruzio.com> - 2013-07-21 21:38 -0700
  Re: Cutting panels Robert Wessel <robertwessel2@yahoo.com> - 2013-07-22 00:39 -0500
    Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-22 01:39 -0700
      Re: Cutting panels Robert Wessel <robertwessel2@yahoo.com> - 2013-07-22 19:09 -0500
        Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-22 20:10 -0700
          Re: Cutting panels Jasen Betts <jasen@xnet.co.nz> - 2013-07-23 14:07 +0000
  Re: Cutting panels Theo Markettos <theom+news@chiark.greenend.org.uk> - 2013-07-22 18:33 +0100
    Re: Cutting panels Spehro Pefhany <speffSNIP@interlogDOTyou.knowwhat> - 2013-07-22 13:44 -0400
    Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-22 19:00 -0700
      Re: Cutting panels Jan Panteltje <pNaonStpealmtje@yahoo.com> - 2013-07-23 10:09 +0000
      Re: Cutting panels Theo Markettos <theom+news@chiark.greenend.org.uk> - 2013-07-23 11:45 +0100
        Re: Cutting panels Theo Markettos <theom+news@chiark.greenend.org.uk> - 2013-07-23 13:46 +0100
          Re: Cutting panels 0bama <0B@nocontrast.org> - 2013-07-23 13:06 +0000
            Re: Cutting panels Theo Markettos <theom+news@chiark.greenend.org.uk> - 2013-07-23 22:19 +0100
              Re: Cutting panels 0bama <0B@nocontrast.org> - 2013-07-24 08:05 +0000
        Re: Cutting panels Spehro Pefhany <speffSNIP@interlogDOTyou.knowwhat> - 2013-07-23 10:07 -0400
          Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-25 01:26 -0700
    Re: Cutting panels Jasen Betts <jasen@xnet.co.nz> - 2013-07-23 14:18 +0000
      Re: Cutting panels Spehro Pefhany <speffSNIP@interlogDOTyou.knowwhat> - 2013-07-23 11:38 -0400
        Re: Cutting panels Theo Markettos <theom+news@chiark.greenend.org.uk> - 2013-07-23 22:32 +0100
          Re: Cutting panels Frank Miles <fpm@u.washington.edu> - 2013-07-23 21:37 +0000
      Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 16:16 -0700
        Re: Cutting panels Theo Markettos <theom+news@chiark.greenend.org.uk> - 2013-07-24 10:37 +0100
          Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-25 01:27 -0700
  Re: Cutting panels Gonadicus <gonadicus@no_spam.com> - 2013-07-23 12:46 +0800
  Re: Cutting panels sms <scharf.steven@geemail.com> - 2013-07-23 04:58 -0700
    Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 16:13 -0700
  Re: Cutting panels Jasen Betts <jasen@xnet.co.nz> - 2013-07-23 13:25 +0000
    Re: Cutting panels Don Y <this@isnotme.com> - 2013-07-23 21:42 -0700

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