🚀 go-pugleaf

 bonobo@Ingres.COM (David Victor) writes:
>I'm trying to make a nice-looking aluminum front panel for a project,
>and I'd like to be able to use rectangular switches, possibly other
>squared-off displays, etc.  How do you cut a perfectly-squared-off hole
>in an aluminum panel?  Is there some home-brew method I'm not aware of?

I do this with Greenlee punches.  They're pretty expensive ($10 to
$300, depending on size/shape) but they work great.  You just drill a
hole, fit some parts around it, and tighten a nut.  Bingo -- clean
hole.  (The expensive punches do weird but useful shapes like DB-25
connector patterns)

Round and square punches can be had in the $25 range at well-stocked
hardware (and sometimes auto parts) stores.  A rectangular hole is
done in several passes with a square punch.

>Also, what's a good way to do the lettering?  I've got a LaserJet, but
>how do you transfer what's on paper to what's on the panel?  

I've had good success with "Stickyback" laser film.  This is a matte
finish self-adhesive sheet which works in laser printers /
photocopiers.  I bought it from:

Saga
Division of Dade, Inc.
Interchange Office Park
400 Highway 169 South
Minneapolis, MN  55426-1199

I saw an ad which included a phone number (which I have since lost)
and called them.  They sent several sample sheets so I ordered a box.

>Recently, I heard about a method of PCB manufacture whereby you print
>your PCB design to some special type of paper, iron it on a copper-clad
>board, and then etch as usual.  Seems to me there might be something
>similar for lettering.

An outfit called "Dark Horse Productions" makes a special toner
cartridge which is designed for heat transfer.  Their target market is
T-shirts, but they say it can also be used for panel lettering.  I
have their sample pack at work; I couldn't get it to transfer to
aluminum very well, though.  Email me if you want their address and
I'll look it up at the office.

There's also a special paper which dissolves in water; you can use it
to make real decals with your laser printer!  It's also been discussed
as a possible PCB etch resist.  I don't have the details but I'm sure
someone will enlighten us...

-- 
----------------------------------------------------
Gordon S. Hlavenka           cgordon@vpnet.chi.il.us
  Don't forget:  Dave Barry/Joe Walsh in November!