Sheet steel control panels

[draco]

In the process of designing the new control panel for my cab, I have come to the conlcusion that the way that best suits the controls I want (1x Ultimarc J-stik, 8 buttons, inset laptop keyboard, inset laptop trackball) is to cut the control panel from sheet steel, probably about 2-2.5mm thick.

I'm wondering if anyone here has cut their own steel control panel, and how difficult it was? I have a bench drill-press and can get good holesaws and drills for mounting buttons, joysticks, etc, and I'll get the basic panel cut to the correct size for me by the local steel supplier; I'm worried however about how to cut a large, rectangular hole for the keyboard to stick out of. I'm not that handy with a jigsaw but could probably manage, the only thing is, I really want it to be as neatly finished as possible.

Any advice would be greatly appreciated.

[Minwah]

There have been a good couple of threads here over the last few weeks about metal panels - try finding them...

Points of note were:

Aluminium of ~3mm thickness is strong enough for a CP, and easier to work with,
Hole punches work best/quickest/neatest to cut circular holes for buttons etc., but holesaw's will do the same job with a little more effort.

I suspect you could cut a decent rectangle by drilling a hole in each corner first, and then using a jigsaw.  If you plan to cover the CP in vinyl or similar, that could hide any slight imperfections in the cut.

Edit:  Check out telengard's modular metal CP's, very cool : http://users.adelphia.net/~bsturk/mame.html

[draco]

Aha! yes, so I see. Should've looked at that lot first really. Next quiestion though; I'm in the UK (Aberdeen, in fact) - any suggestions as to where I might find a good (i.e. cheap) aluminium supplier who'll sell me a bit of 3mm plate cut to size?

[Minwah]

Aha! yes, so I see. Should've looked at that lot first really. Next quiestion though; I'm in the UK (Aberdeen, in fact) - any suggestions as to where I might find a good (i.e. cheap) aluminium supplier who'll sell me a bit of 3mm plate cut to size?

I'm UK to...but can't help you I'm afraid

I once bought some machined sheet aluminium from a place called 'Europa Specialist Spares'.  They do automotive stuff - from memory they are not cheap tho, and you probably wouldn't want the finishes they have.

I would recommend cut it yourself tho.  I did this myself with a jigsaw having never done it before and it came out perfect

[telengard]

In the process of designing the new control panel for my cab, I have come to the conlcusion that the way that best suits the controls I want (1x Ultimarc J-stik, 8 buttons, inset laptop keyboard, inset laptop trackball) is to cut the control panel from sheet steel, probably about 2-2.5mm thick.

I'm wondering if anyone here has cut their own steel control panel, and how difficult it was? I have a bench drill-press and can get good holesaws and drills for mounting buttons, joysticks, etc, and I'll get the basic panel cut to the correct size for me by the local steel supplier; I'm worried however about how to cut a large, rectangular hole for the keyboard to stick out of. I'm not that handy with a jigsaw but could probably manage, the only thing is, I really want it to be as neatly finished as possible.

Any advice would be greatly appreciated.

As Minwah mentioned aluminum is much easier.  I used to have plate steel panels and they
are a *total pain* to work with.  Holes took about 10 minutes+ with a hole saw and drill press on the slowest setting, even using cutting oil.  Aluminum cuts like butter and is much easier in general to work with.  I used standard rack mount peices for mine so I don't know about where to get an arbitrarily sized piece of alum.

Hope this helps...