Project box ideas?

[PotatoBox]

Hi,

So I'm building a variable power supply and I'm having a little trouble finding a suitable project box. All the project boxes on ebay are too small as I need a rather tall one that can fit the ammeter (a Weston electric one, its a black, round one) which is about 3.5 inches in diameter and the voltmeter, which is the run of the mill square plastic one. The only suitable one on ebay is this one:

http://www.ebay.ca/itm/Electronic-Project-Enclosure-DIY-Power-Junction-Box-Case-Blue-250-x-190-x-110mm-/371916400363?hash=item5697f1e6eb:g:wqsAAOSwnF9Y62Aw

But I'm looking for a plastic one rather than metal because I don't have the proper tools to cut through a metal box.

Any ideas?

[kalel]

I didn't find exactly 250 x 190 x 110

But looking at "large plastic enclosure" from China I was able to find the following:

http://www.ebay.com/itm/Waterproof-Clear-Electronic-Project-Box-Enclosure-Plastic-Case-265x185x95mm-/291576595522

265x185x95

http://www.ebay.com/itm/Plastic-Waterproof-Electronic-Project-Box-Enclosure-Cover-Case-230x150x85mm-/291576471537

230x150x85

But there might be more with the same/similar search.

[Neomys Sapiens]

There is always a last resort without having access to sheet metal bending gear:
get 10x10mm steel or aluminium rod, cut into 10x10x10mm cubes, drill and cut threads on 3 adjacent perpendicular sides..
and use those and flat sheet metal to build box of selected size per demand.

(just a mechanical improvisation technique I used once when I had to make something quickly to a certain size)

[DaJMasta]

It's worth noting that most plastic/wood cutting/drilling tools will also do the trick with aluminum boxes, since it's a very soft metal.  Could give you some different options to look at as there tends to be some availability of them, at least through medium sizes.

I sometimes find it good to look at a specialty container store - while normal storage boxes and bins wouldn't have a good look for a project, you can sometimes find some that are more suitable (straight edges, for example) at stores that specialize in storage items.

[texaspyro]

I REALLY want somebody to build my dream box.   Front panel big enough to mount the Raspberry PI 7" touchscreen and space for some BNC connectors, USB ports, knobs, etc.   Back panel should have a cutout for an IEC / filter / switch module and a fan cutout or two (40 mm?).  Ideally front/rear panels should be replaceable / configurable.  A tilt handle would be nice.  Box should be like 9-12" deep.  Metal would be best. 

You could do something like it with places like Front Panel Express,  but the cost would probably be $100-$200.

[kalel]

I assume there are some (heavily priced) websites where you could send your design with cutouts and get a custom box?

Ah, wait, I'm probably thinking about 3D printing then.

[Gyro]

But I'm looking for a plastic one rather than metal because I don't have the proper tools to cut through a metal box.

Any ideas?

Please don't rule out diecast aluminium boxes. They're rigid but really easy to drill and file, no burrs at all. I'd prefer making holes and cutouts in diecast rather than plastic or sheet aluminium any day.

[Teledog]

Dollar store?
They sometimes have large wooden boxes also (they sell out rather quickly)
Made a couple of projects with them.
{I'll get dissed for making a wooden "plating rectifier", but plating solutions generally corrode the h*ll out of any metal case in a short period of time}

[DaJMasta]

In the same vein, maybe it's worth checking a thrift store if you think a retro-looking box could work.  Totally random whether or not you can find something suitable, but it will probably be cheap.

At least in my experience, drilling aluminum always leaves burrs.... but the burrs can be cleaned with a little sand paper or an xacto knife because of how soft they are.

[ajb]

I REALLY want somebody to build my dream box.   Front panel big enough to mount the Raspberry PI 7" touchscreen and space for some BNC connectors, USB ports, knobs, etc.   Back panel should have a cutout for an IEC / filter / switch module and a fan cutout or two (40 mm?).  Ideally front/rear panels should be replaceable / configurable.  A tilt handle would be nice.  Box should be like 9-12" deep.  Metal would be best. 

You could do something like it with places like Front Panel Express,  but the cost would probably be $100-$200.

Metcase, OKW, Pentair, Phoenix Mecano, and others all do boxes like you describe.  Takachi, Hammond, and Bud might as well.  They may or may not wind up costing more than $200, though, especially after customizing.  When you consider that one of that style of case might consist of a dozen different stamped, folded, die cast, and/or machined parts chosen a la carte from a menu of 50 optional parts available in five color and finish options and the combination is sold in single piece quantities, that's not a bad price at all.

Takachi, Lincoln-Binns,  and Phoenix Mecano (the latter under the Rose Bopla brand) also do large-ish aluminum extrusions that just need front and rear panels added.  Those can be had for <$100, especially if you're willing to make the end panels yourself.  If you want a large enclosure on the cheap, you're going to have to be willing to spend some quality time with a drill, jigsaw, and a set of needle files.  Or find a CNC machine you can use.

[Neomys Sapiens]

I personally like the enclosures made/sold by Feltron Zeissler, but I cannot say if they have any representatives or distributors where you need them. Maybe inquire directly if they can provide you with information where to buy.

Solidly made, uniform style, very practical construction:
http://www.feltron-zeissler.de/mechanik/kleingehaeuse