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Our DVD shows you several ways to cut and shape aluminium panels. Here, I'm trimming to the line with snips. Don't cut directly to the line with the first cut or you'll distort the material. Make two or three cuts so the the final trim to the line is just a couple of millimetres. Finish with a file if necessary.
Picture 1 shows the two halves of the box 'Cleko'd' together. I've cut a large hole in one side as the air inlet to the matrix and I've mounted two bulkhead flanges on the opposite side as 'outlets'. There's plenty of room to mount more as you wish.
I've also cut two pieces of 25mm x 25mm ali angle as mounting feet.
Picture 2 shows the inside of the box and the short screws and nuts used to fit the flanges. To secure and seal the matrix, I've used our #TRMDSA3 hollow 'D' section, self- adhesive trim. This locates and holds the matrix securely in position away from the box sides and any protruding fixings. Pictures 3 and 4 show the front and rear of the assembly.
Here, I'm using a step drill for the 25mm holes. Step drills can cut very clean, accurate holes and you can deburr them by turning over the panel and making a light cut on the other side.
If you have access to a bench folder or even a box and pan folder it'll make the next stage very easy. If not you can make very neat folds using two pieces of angle iron in a vice. Clamp the aluminium between the angle iron on the fold line and use a piece of two by two timber, sitting on the angle and a hammer to 'dress' over the fold. For shorter folds use a short piece of angle.
1 To order Tel: 01580 891309 or 07964 336183 or Fax: 01580 893733 or online at www.cbsonline.co.uk ISSUE 26 Page 273