Well it is that time again, another day means another update. unfortunately I had to call it quits early today because the hardware store close to my house is closed by 6 pm.
I skipped a lot of the small details like actually cutting the metal to shape and size but I had taped a twelve by twelve inch steel sheet (18 gauge thick I believe) using blue painters tape this way I could easily outline the part and cut it out. Next I did a few of the bends to allow for a test fit
I was always running into small snags with the part not fitting right so I would constantly be putting the part in, taking a look, pulling the part out, and bending it with pliers or hitting it with a hammer. Sometimes I would run into the issue of having too much extra material and have to take small trimmings off (this is actually a good thing as I can always remove material but can never add back to it without a welder)
after I could no longer tell how the part would fit by just setting it in the location it will be living in, I marked the spots to be drilled, made the holes and removed the tape. (by this point the tape was already messed up and just needed to be removed as it no longer was able to be of use)
I had ran into two new issues after mounting it into the case for the first time, the first thing that is obvious is also a HUGE thumb sore. That damned gap was huge, and that part was at an angle so the back side against the motherboard tray was fine.
But wait, that is only one issue.. so what is the second?
Well, the radial bend on the power supply shroud was larger then what currently exists on the part I made. which would explain the gap problem as well.
Alright so now knowing what was casing the issue I quickly removed the part from the case and did a little hammering, bending and repeating with trying to make the radius larger. slowly I worked the metal into shape. Voila, with time and effort I have managed to make a working part from one piece of steel.
And so now we have reached the point that I need to get some Bondo or similar thing to fill in the small gaps and smooth out some rough spots.