Re: Cutting panels

From	Don Y <this@isnotme.com>
Newsgroups	sci.electronics.design, comp.arch.embedded
Subject	Re: Cutting panels
Date	2013-07-21 17:07 -0700
Organization	Aioe.org NNTP Server
Message-ID	<ksht44$3pl$1@speranza.aioe.org> (permalink)
References	<ksganq$383$1@speranza.aioe.org> <3ksou89mqn88v4o9s9st04hh31os3tdp87@4ax.com>

Cross-posted to 2 groups.

Show all headers | View raw

Hi Spehro!

On 7/21/2013 4:45 PM, Spehro Pefhany wrote:
> Hi, Don:-
>
> Protocase does this sort of thing at a fairly reasonable price-
> they'll put markings on too. I think frontpanelexpress.com as well,
> but never tried them. They use CNC punching so you get almost smooth
> edges (a bit of a burr where the successive punch hits overlap, which
> could be smoothed off with a file, but is usually unnecessary).

Ah, so they sort of tackle it like an oversized "nibbler"?

> You could also make a relatively crappy panel with a scroll saw and
> file (lots of light, magnifier lamp or safety glasses up close, and
> clear the chips often), and cover it with a (eg. plastic) bezel that
> is thin enough to cut with an Xacto(tm) knife.

Yes.  I think this is the right approach.  Separate the cosmetic from
the structural/functional.

In my case, I can take a pair of panels and cut each slightly beyond the
halfway point.  E.g., given something LIKE:

<http://www.genesistems.com/office/pics/PatchPanel.JPG>

imagine cutting vertically, halfway between the "13" and "14"
markers.  So, you end up with as much "panel" extending to the
right of the 12th (and 36th and 60th) connectors as you do to
the left of the *1st* connector.  This acts as an "ear" with
which the panel can be mounted to <whatever>.

[You must cut *outside* the "black dots" that mark the locations
of the studs/standoffs/bosses onto which the PCB *behind* the
panel is fastened.  And, still leave enough material to provide
a mounting surface]

But, cutting at the 13-14 point leaves you with a real mess!
I.e., the right edge of this new panel now has these big cutouts
into it (for connectors #13, #37, #61, #85).

If, however, you can apply some thin sheet of plastic (0.062")
over the whole thing, it *appears* to be a much finer product.

[The connectors can be coaxed into protruding further through
the panel -- to align with the outer surface of this plastic
overlay -- by trimming down the standoffs on the rear of the
panel]

> I assume you're using
> something like 3mm hard Al so hand punching or pneumatic nibbling
> would be a bear.

Exactly.  Trying to "machine" it turns it into a project of its
own!  (sort of like making your own spark plugs *before* you
start on that tune-up!)

> Oh, and use appropriate file sizes and the type with
> no teeth on the sides so as to get sharp corners. A skilled person can
> do wonders with a file. ;-)  Supposedly one 'hiring' test for
> machinists was to make a square peg and square hole with nothing more
> than a file and a hacksaw. Had to fit within a thou or two to pass.

I'd rather come up with a solution that lets more folks achieve
"acceptable" results than require people to expend a lot of effort in
something as "unimportant" (?) as a "device to hold connectors".  I
think the more you can do to cause "good" results encourages people to
undertake projects that by which they might otherwise be intimidated.
E.g., the "Photoshop overlay" lets folks feel like they've done
something completely unique -- without having to understand some
other (more important!) detail...

This also lets folks adapt the solution to their particular needs
and the materials that they have available to them.  E.g., I also
have a bunch of 12-port panels intended for vertical orientation.
Rotate them 90 degrees and slap something on top and no one knows
that the *obscured* legend is now "sideways".

Keep cool!  Regards to wife.
--don

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

csiph-web