mlaws' controller enclosure-warning lots of photo's

[Mcgyver]

I started this new thread to show Mike’s (mlaws1172) controller enclosure because it deserved decent photo essay (or at least my attempt at one ) but didn’t want to bog down the other thread.

Being on the other side of the continent and across the border, I had to wait patiently for the much talked about enclosure, but it was worth the wait. The workman ship is first class imo and I learned a lot on sheet metal by seeing how an experienced guy goes about it. Mike, thanks for a great job and Dan thanks for helping out in the supply chain.

Here’s a shot of the components as they arrived. The box was well packed with an inch of Styrofoam on all six walls of the package and arrived without damage.



This may not be the right terminology, but sheet metal gets nice and strong when there are lots of profiles and high crown areas. Check out this corner of the bottom – lots of doubling up and high crown/bends! The exposed edge running along the right hand side of this shot neatly slips into a pocket formed along the bottom of the side



Here’s the bottom of the side showing the pocket



And how there go together with a very nice fit



Here’s a shot with the sides in place – lots of spot welding going on. This also gives a good view of the 4 Z shaped piece spot welded to bottom ; adds a lot of strength and is the shelf the false bottom sits on.



There are two cross members that go across the front and back, each of which has many folds, making a strong structure



This completes the chassis – one of the nice features is that the AL front and back, hinged lid and false bottom all attach to the chassis but aren’t really integral to it. After taking all these shots, I noticed the left side of the front member is not aligned in the pic. The reason is that this assembly is only a mock up and I didn’t notice this until after. It’s a mock up because I plan breaking it down for priming and painting



The lid is nicely folded over with the corners welded. Needless to say all explosed sheet metal edges are folded over through out



The false bottom also has 90 degree angle pieces spot welded to it and it very sturdy.



Finished assembly, note the stainless trim on front sides and top (well I guess this shot doesn't show the front of the top, but its there). Key features include a hinged top, detachable aluminum (so its easy to cut) front and back panels and full false bottom



I hope this is of value. I couldn’t find a decent enclosure and Mike’s design has nailed it imo so wanted to share some detailed pics

[Weldtutor]

These controller enclosures by Mlaws1172 certainly are an excellent piece of quality fabrication.
Being another satisfied owner of an enclosure from production run #1 I'll second all of your comments Mcgyver. Thanks also for your suggested design features included by Mike.
For those interested in seeing a finished enclosure mine is pictured in the Plasma Forum for my table build log. Mike also posted finished pictures in the other thread you mentioned.
WT

[bill south]

I too have one of Mike's excellent enclosures and am in the process of converting from a almost finished brand x enclosure to Mike's. I decided on using a new box after hours of tryng to fit everything into my first enclosure. Needed a shoehorn and some vasilene. My only problem with the new enclosure is what to do with all the room!!!! I've placed and replaced all the boards and compoenents and still lots of blank area!!! The entire layout is on the bench being built on the false bottom and will be transplanted to the enclosure as soon as I'm finished. Wow, is it easy to work with. Pictures promised but I'm going to wait for the final completed project. Thanks again Mike.
billyjack