[Heathkit] Apache or Warrior panels

[Bob Macklin]

I use Devcon aluminum filled epoxy to fill unwanted holes. McMaster-Carr has
it.

Bob Macklin
K5MYJ
Kent (Seattle), Wa,
"Real Radios Glow in the Dark"

----- Original Message ----- 
From: "rbethman" <rbethman at comcast.net>
To: <heathkit at mailman.qth.net>
Cc: "John Hensley" <w5jv at hotmail.com>
Sent: Thursday, December 18, 2008 12:06 PM
Subject: Re: [Heathkit] Apache or Warrior panels


> John,
>
> Using EITHER Mig or Tig welding methodology would VERY likely cause
> warpage.  The reason is the concentration of heat in particular areas.
>
> One way too deal with this would be heat treating the panel AFTERWARDS.
> Welding aluminum causes almost immediate expansion due to its
> properties.  It coefficient for heat expansion is pretty high.
>
> To use one of those panels, consider using a hardening body filler.  You
> can always cut a piece of aluminum screen to occupy the hole, the apply
> the body filler, IF you are having issues with RF.
>
> There is of course the possibility that welding being difficult because
> we do NOT know what specific alloy of aluminum was used.  Most likely it
> varied widely.
>
> Another thing to think about, plug welding WITHOUT a backing plate
> increases the difficulty.  The individual performing the welding would
> be trying to build up the weldment by adding molten metal to the edge of
> EACH hole to bring the hole to a close.
>
> Bob - N0DGN
>
> John Hensley wrote:
> > Has anyone been successful wire welding hole inserts into the Apache
> > or Warrior panels in order to reuse them for another purpose?
> >
> > I'm familiar with filling unwanted holes with various compounds and
> > then refinishing to give the "appearance" that the panel is solid.
> >  I'm curious if in a project anyone has taken one of these 3/16"
> > panels and been successful reclaiming them with wire welding ?  Part
> > of the interest is to find out if they can take the heat without
warping.
> >
> > I'm getting ready to build a homemade KS-1 power supply and will be
> > using an old Apache cabinet to house it in.  By the way, if anyone has
> > the same project on their "to do" list, Harbach is geared up to
> > reproduce the original plate transformer.  If a few builders could be
> > found, we might be able to get a better price on the xmfr.
> >
> > TIA, John
> >
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>
> -- 
> Bob - NØDGN
>
>