An update...and it's been a long time coming! I have finally made an investment in getting all the tools I need for this project - a Dremel 4000 with a Drill Press, Multi-Vice and other useful accessories that came in a neat metal toolbox:
The 4000 is very useful because the variable RPM is between 5,000 to 35,000. Aluminium drilling & tapping wants a very low RPM and lots of torque from what I've understood. However the deepest holes will be no more than an inch deep (in the sides of the pedal base to mount the Hammond Project boxes) with the largest diameter being 10-32 (for a UNF thread grub screw to mount the acorn nut at the foot of the pedal base) so I'm hoping the lowest RPM at 5,000 will be ok for this work. However the metal Project Box wants a 1/8 NPT thread drilled and tapped at either end but this is composed of die cast metal; hopefully I can use the Dremel successfully here also. I have just about managed to fit all these tools in the cupboard, out of the way of the missus when not in use lol. So anything larger is out of the question [emoji51]What I do still need to sort out is a mounting block for the Drill Press, some dust sheets and some metalworkers dye (Marking Blue, Layout Stain or Prussian Blue), to help with marking out the dimensions for drilling & tapping with a scriber.
I have been doing quite a bit of research (still ongoing) into the correct processes that are involved for drilling and tapping aluminium, and I will be getting some scrap pieces in order to practice on first. I am using a very handy engineering pocket book that I've had for many years (from College days), an Osborn Cutting Tool Guide, which has a wealth of relevant information regarding metalwork, with drill speeds, drilling methods, tapping and thread sizes:
[imghttps://lh6.googleusercontent.com/SZ2RE6cuz7Hpe0HyKz7iiLu7SpZYttQdnkyAhtsg4CZKB8LEqQ4tgtaKQF2SlcQms6MZGBZTzJBr1-fh1TqSrw=w2880-h1570img]
I've never used this book and now it couldn't be more useful!
Other items I've bought are:
-Metal Rule
-Carbide Tip Pocket Scriber (for marking the initial points on the metal for the hole positions)
-Centre Punch (for impressing the hole positions into the surface of the metal for accurate drilling)
-Modelling Knife
-Safety Goggles
-Cutting Mats (A3 & A4)
-Industrial/Professional grade metal cutting fluid (non-soluble for aluminium)
-Tap Wrench
-Set of taps for 4-40 UNC threads with drill bit, made from HSS (High Speed Steel). These are very expensive but are again professional grade and they will give many years of service if used correctly. I need to obtain quite a few sets, not just other UNC sizes but also UNF (10-32), NPT (1/8) and for countersunk machine screws (I think), used for mounting the pedal vector plate to the hinge and base. So I will have to add these slowly to the inventory, given the cost involved!
I've included all this detail for the benefit of anyone else who may be starting out for the first time, and would find this info helpful [emoji4][emoji106]
Regarding Trap parts, I have also obtained:
-Tower Pro MG90S Micro Servo motors for the door mechanism (x2)
-G-Force GF-2120-003 Small Control Horns (x2)
I still need to order the Hyperdyne Labs light & trap door electronics kit (maybe next month)
I was looking at nosllitt's epic aluminium trap build thread quite a lot and decided that I really liked his method of mounting the hyperdyne bargraph lights with the use of a VCC Panel Indicator Mount, obtained from Allied Electronics. The indicator was stripped for the clear plastic panel which is a perfect fit for the bargraph lights:
I fully appreciate that the discovery was made afterwards revealing the actual bargraph used for these original props, and I assume that nosllitt may have retrofitted his trap with the very expensive, accurate part, which incorporates a black bezel surround - accurately represented in Spongeface's bezel kit, but I just really like the look of this setup, which is quite simple too!
Finally, I have been working with Chris (CPU64) for the last 3 months or so in obtaining some aluminium side plates and doors. The plates have been cut and the doors are being done at the moment. CPU has gone to an extraordinary amount of effort in creating some highly accurate doors which closely match those that are seen on the Propbay Hero GB1 Trap. When these arrive, I'll document everything that went into getting these made in full detail, together with all the measurements that were used so that they are compatible with Nick's resin kit, but needless to say, they are stunning! [emoji4][emoji122]
A set is also being made for a fellow Ghosthead, damster117, who is also building a GB1 trap based on Nick-A-Tron's resin kit (and is miles ahead of me lol), he has been immensely helpful with everything so far and has supplied so much info for this build project...
Phew! That's it I think, for the moment. Oh yeah - I still need to obtain Nick's resin trap kit lol. I've put this last because I've been attempting to nail all the tricky greeblies first. I do have all the parts needed to start the pedal though, so I will get the tools set up and start practising my drilling techniques [emoji12] I really don't want to screw up any of those precious parts, so bear with me.
More soon! [emoji4][emoji106]