Update!

prototype is finished and has been shipped! Will post pictures as soon as I recieved it. Prototype price will be updated to include shipping on the spreadsheet. This should only add 37 cents to the price.

Enclosure has arrived! Its a raw brushed metal which actually isn't that bad.

Good news is the front and rear panel layout is fine. Except for a slight issue with the power switch. And that's only a problem because the way I soldered it makes it tilt slightly up. Because of this the cap rubs a bit with the panel. I can easily fix this by making the diameter 1mm wider or just using a smaller button cap. (Or just solder better)

The bad news is that the side panels don't quite fit. Partly because I did not receive a good CAD drawing for the side panel, so I did not take the stud for the top and bottom screws into account.

It doesn't touch the PCB, however it does interfere with a screw I use to secure the IEC to the PCB, as well as some pins under the source switch. But this can easily be resolved by making the case wider. I can also use the 3.5" tall case they offer, however that will increase the cost quite a bit and will have a lot of empty space.

I'll take the screw off the IEC and cut some pins to post pics of it completely enclosed. Drawings will be updated by this weekend and hopefully we can put a final order in by next week. We could also get another proto but that's an additional 3 weeks and $3 per case. I don't think we will need another proto.

Would you like me to get a quote from CAM Expert based on johnwmcleans FPE plans (known to work)?

16 minutes ago, Pars said:

Would you like me to get a quote from CAM Expert based on johnwmcleans FPE plans (known to work)?

Yeah, you can check. ~40 enclosures. Somewhat doubtful it would be under $100

Probably, but with Heinz, it seems to depend upon day/mood

I'll give him a shout. How many TKD/Alpha?

28 minutes ago, Pars said:

Probably, but with Heinz, it seems to depend upon day/mood

I'll give him a shout. How many TKD/Alpha?

Its all on my spreadsheet. 21 TKD and 19 Alpha.

Got the amp assembled 

After cutting some leads and removing the IEC screws, everything fit fine. There's some small gaps here and there, but at this price point I think it's acceptable and you wouldn't really notice unless you look really closely.

After running it for a couple hours the case can get pretty warm. Even the potentiometer starts feeling warm. I'll try it without the top cover to see what i get. Either way, the next revision is getting a lot more holes.

Very nice case.  I love the fact that it keeps the footprint of the mini very small.

There isn't enough room under the board for screws in the IEC? What is the dimension from the bottom of the board to the case bottom?

It's only because of the stud on the side panel for the screw. Which isn't an issue anyway because I need to increase the width for more airflow. The screws I used for the IEC were kinda long too.

Ahhh, gotcha. Carry on

Nice work!

I wasn't planning on using the screws from the IEC to the board, just the IEC to the back of the chassis.

You could also use some button head cap screws coming from the bottom up, which would be pretty flat.

I'm with @Kerry on this one - can't see much sense in PCB screws, if it's well fastened to the back panel.

Great work overall!

Yeah, they don't really need to be there after it's mounted. I do use them to hold the IEC in place for soldering and it takes some pressure off the pins when I was using it without an enclosure, but are otherwise optional.

I’ll probably do the same.
I did get a quote back from Cam Expert. They would run at least $200/case... not even competitive.


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Just wanted to let you guys know I haven't disappeared. Updating is just taking a little longer then expected with life. I did get in contact with the manufacturer and he said my modifications won't affect the price too much.

We weren't worried about you disappearing

I know these group buys are a lot of work (for you); take your time and make sure things are where you want them before pulling the trigger.

Hi Gael,

Status on this? This is getting to be somewhat ridiculous regarding time line as there was a known good design in johnwmclean's, known vendors (though certainly not as cheap), etc.

Please provide an update, and thanks. I know running group buys is a pain in the fucking ass, but it is what it is.

Please Gael, some of us really want their cases sooner than later.  Thanks again.

Sorry about the radio silence. You guys are right, it's not cool when I'm holding other people's money.

I'll just say this. I got a lot of stuff going on and I would have honestly preferred joining a group buy rather then starting one. No one else was doing it, so I did. Yeah, modifying drawings does take time. But not this much time.

The current design works. Everything fits and the front and rear panels are accurate. It does get a bit hot, however with the cover off it runs fine. So I'm going to maximize the vents on top and bottom like in the following PDF

dynalo_top_plate_15.pdf

I'll order this by Monday when they open back up. IF I haven't completed this order by Wednesday, I will refund everyone's money and I'll absorb the cost of the prototype. I'll even have the prototype for sale. The drawings will remain for anybody that wants to go through Enclosures and Cases Inc themselves. They should also work at fine at Context Engineering.

@Pars - You will also get your panels with countersunk holes. Just let me know which holes you want countersunk. This goes for anyone else as well.

 

Edited June 2, 20188 yr by cspirou

I think you should widen the case as you planned to do. The additional venting for the top cover is probably wise as well. Just keep us informed as to progress and post the final design files when you are ready to place the order. Thanks!

The original post has updated drawings. Look over it for errors

I widened the case to 6.5". Also decided to go brute force with ventilation and added a lot of holes on the top and bottom panels. Diameter for the power button has been widened a bit from 10.5mm to 11mm.

Besides the text, the issue I need feedback on is the power LED hole. I have it at 2mm right now, but it seems small and limits the kind of LEDs people can use. Should I keep it at 2mm or go bigger?

Sending this in for a quote

I’ll take a look at these tonight.

As for the LED hole, the std. LED is a T1 3mm round. I had wondered whether a 2mm hole was big enough for these, but johnwmclean used the same for his...

 

 

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Took a look at them (cursory); they look good!

LED hole would better be 3mm as most common leds are 3mm.