[Milsurplus] A Classic Example of the Homebrew Art

Mon Sep 28 19:59:23 EDT 2020

Aluminum up to ½ inch thickness cuts quite well with a decent carbide blade in a table saw.  Just beware of the chips, and take proper precautions.

Milwaukee tools has a STEEL CUTTING “Skil Saw” that will cut 1 inch steel plate, and cuts ¼ inch plate about as fast as cutting ¾ inch plywood with a normal saw.

Well worth the money.

R

From: milsurplus-bounces at mailman.qth.net <milsurplus-bounces at mailman.qth.net> On Behalf Of MICHAEL BITTNER
Sent: Monday, September 28, 2020 7:27 PM
To: B. Smith <smithab11 at comcast.net>; Milsurplus <milsurplus at mailman.qth.net>
Subject: Re: [Milsurplus] A Classic Example of the Homebrew Art

I know this is off topic for Milsurplus, but this thread started here, many are following it, and many surplus components windup in homebrew radios such as K4CHE's use of ARC-5 IF transformers in his excellent HBR receiver.

Sticking to Sean's original questions about tools, note that K4CHE uses angle stock or other pre-bent material as  neat work-rounds for not having a large bending brake when fabricating the cabinet (or chassis) for his HBR.  You still have to cut the various sides to size and that may take a portable jigsaw or band-saw to rough them out and then file them to final shape with a flat file.  I had to use this procedure for the front panel of my regen since it is too thick for cutting in my sheet-metal shear.

Sheet-metal Vise-grips are OK only for small parts that can fit within their jaws and throat depth.

You know you are ready for the advanced level when you become dissatisfied with the ARRL Handbook recommendation of placing your sheet metal between two hardwood blocks in a vise and bending it with a ball-peen hammer.  I works and may be good enough for you, but the projects in the handbooks were actually built in a well equipped shop with professional tools. 

Wood cabinets can become  shielded cabinets by sticking aluminized paper or aluminum foil to their inside surfaces.  

Nowadays, you can build all kinds of transistor stuff with no more building skills than being able to cut, etch, and solder printed circuit board material.  You can even make perfectly shielded cabinets by soldering but-jointed pc boards together at their inside joining edges.

Mike, W6MAB

On September 28, 2020 at 5:28 PM "B. Smith" <smithab11 at comcast.net <mailto:smithab11 at comcast.net> > wrote: 

 I got obsessed with a 1957 QST project. Used basic hand tools -  even the cabinet is HB. The rat tail file is my favorite tool. 
k4che 
http://k4che.com/HBR/HBR%20page%201.htm 

On 9/28/2020 2:11 PM, MICHAEL BITTNER wrote: 

Sean,
I agree with Mike Feher that there is no "break even point".  You build stuff because you like to build stuff.  If you are only interested in operating, then buy an appliance and operate it.  Don't waste you time and money on building, and certainly don't buy expensive tools that you may use only once.

As indicated by Al Klase, there are many simple entry level projects that you can build with ordinary hand tools and scrounged parts.  If you build one of these, it shows that you are interested in building and you may want to advance to more serious homebrew projects. The subject transmitter/receiver is well above the entry level.  Here are some photos of one of my more complicated homebrew projects and below are listed the tools I used to to build it:

https://photos.app.goo.gl/KHoNsugHNHzBed6V9

https://photos.app.goo.gl/MiMHgyMZRe9Lvpra6

https://photos.app.goo.gl/UpYKJ34kQ5boxTNTA

https://photos.app.goo.gl/GwUbQARu7dq6rNcP6

In addition to the tools listed by Nick England (nibbler, rat-tail file, etc.) I used a toolbox full of hand tools plus some machinery including; drill press, sheet metal brake, sheet metal shear, rivet gun, table saw, router, jig saw, Greenlee chassis punches, bench vise, random orbit sander, and probably more that I can't think of at the moment.  I cut the large opening in the front panel for  dial illumination by drilling a series if interconnecting holes around its periphery and then smoothing it out with half-round files and sandpaper.

Mike, W6MAB

On September 28, 2020 at 12:27 AM Sean Kelly  <mailto:Captain.Kelly at outlook.com> <Captain.Kelly at outlook.com> wrote:

I love it! I've always wondered, since I didn't take metal shop, what tools one needs to build like that? I do know a person can have it done commercially, the question is where is the break-even point located?

Sean

________________________________________
From: milsurplus-bounces at mailman.qth.net <mailto:milsurplus-bounces at mailman.qth.net>   <mailto:milsurplus-bounces at mailman.qth.net> <milsurplus-bounces at mailman.qth.net> on behalf of Al Klase  <mailto:ark at ar88.net> <ark at ar88.net>
Sent: Sunday, September 27, 2020 1:02 PM
To: Milsurplus at mailman.qth.net <mailto:Milsurplus at mailman.qth.net> 
Subject: [Milsurplus] A Classic Example of the Homebrew Art

Gang,

Not really military, but I've been obsessing over an artifact from 1951
QST, *Take a look*
 <http://www.skywaves.ar88.net/homebrew/Homebrew_Projects.htm> <http://www.skywaves.ar88.net/homebrew/Homebrew_Projects.htm>.

Al

--
Al Klase – N3FRQ
Jersey City, NJ
http://www.skywaves.ar88.net/

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