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Saturday, 4 August 2012

Radion PSU Shelves

I had a dream recently, a dream about a neat idea to locate the Radion PSU's, it sounded great. Then i woke up, and realised it was a nightmare. You see the "thing" i created a few posts back is hideous... i hated it from day one... regardless of the fact it will be completely out of sight when in situ!

I could not live with myself knowing a bodge job effort was leaving a skid mark on my meticulous planning, being a perfectionist is a curse!

So...

Radion PSU Shelves Mk.2

I went back to step one and returned to how i was going to do it, until i found some scraps, odds and ends in the garage...

And ordered some cut acrylic from Cut Plastic Sheeting who might i add, provided an excellent product at an excellent price. Also delivered next day when originally quote for 5-6days! Excellent, will use them again in future for following similar projects.

Radion PSU Shelves - 1

A perfect fit…

Radion PSU Shelves - 2

In glossy white…

Radion PSU Shelves - 3

Acrylic is a dream to work with if you have plenty of good quality clamps!

Radion PSU Shelves - 4

A work bench and a bottle of Tensol 12

Radion PSU Shelves - 5

A bead of T12 was applied along each edge, then left for 5 minutes or so, followed by some strategic clamp repositioning...

Radion PSU Shelves - 6

This was the "test", within 20minutes or so it was pretty much rocks solid and more or less 1 piece of acrylic, as this is done by solvent welding rather than adhesive :)

A Radion PSU being measured up for its hole positions...

Radion PSU Shelves - 7

Holes marked and centre popped...

Radion PSU Shelves - 8

Clamped back to the table, ensuring the hole position was over one of the bench holes

Radion PSU Shelves - 9

I found a use for the pap thing i made earlier  saved its grace from being smashed to bits by throwing it at something solid!

Radion PSU Shelves - 10

Sometimes you get discharge!

Radion PSU Shelves - 11

But no need to crack out the Vagisil, the soft stuff can be sliced off with a blade, then some wet and dry can smooth it out, you could smooth and polish the edge completely. I didn't bother... after all... nobody will ever see it…!

Radion PSU Shelves - 12

Radion PSU Shelves - 13

Measuring up for the other two PSU's…

Radion PSU Shelves - 14

Spacer pieces ready to be bonded…

Radion PSU Shelves - 15

In the mean time while going through the drying periods, i got all the "shelves" drilled…

Radion PSU Shelves - 16

Now to get them bonded…

Radion PSU Shelves - 17

Literally two 5mm wide edges will be the only interface supporting the whole weight of each PSU, then again, if this is done right, it should be rock solid and take some force to snap them back off when fully cured…

Radion PSU Shelves - 18

A novel method of ensuring the solvent weld wicks into the gap rather than running across the surface :D

Radion PSU Shelves - 19

More clamps, this time to hold the shelves in place and keep the pressure on the solvent weld…

Radion PSU Shelves - 20

Rinse and repeat for the other three of course...

Radion PSU Shelves - 21

Load test... passed!

Radion PSU Shelves - 22

Leave it overnight to fully cure…

Radion PSU Shelves - 23

Next day, all good, solid as a rock…

Radion PSU Shelves - 24

More novel ideas! Using stationary not to the intended manner to align cable clips!

Radion PSU Shelves - 25

Ready for the PSU's…

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Decided on a couple of cable ties to keep the PSU's secure, did originally anticipate using nuts and bolts, but these are more than adequate and easier to remove should the need arise…

Radion PSU Shelves - 27

All set and ready...

Radion PSU Shelves - 28

Power cables added...

Radion PSU Shelves - 29

Hood set at a jaunty angle, trust me the room for manoeuvre is around 5mm at the narrowest point!

Radion PSU Shelves - 30

Moved wiring jobs to the top of the hood as i couldn't be bothered undoing the Radions themselves! Wasn't really any issue...

Radion PSU Shelves - 31

Lowered to the first stage at the edge of the tank…

Radion PSU Shelves - 32

Then as i stood off the chair, lowered it to the ledge at the bottom of the cabinet, a few short strips of thick tape (double sided stuff in this case but with one side still covered). As the back piece is pretty much the same height as the gab its in, a quick shove meant it squashed into the tape and wedges in pretty much solid, yet a quick tug will release it…

Radion PSU Shelves - 33

Done! Feed the plugs round the back ready for going into sockets…

Radion PSU Shelves - 34

Bang tidy!

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