enclosures and knobs update;4 models and ten knobs.

[sean k]

http://photobucket.com/albums/y115/quickkiwi/?action=view&current=enclosures.jpg
 I dropped off 15 prototype knobs at the foundry the other day,shouldah got some photos but I forgot,and will have 232 little bits of metal next week sometime.
New Update
 There'll be ready tomorrow but today I dropped in and these are the knobs that will come back to me in metal.
http://photobucket.com/albums/y115/quickkiwi/?action=view&current=knobs22.jpg(also in the 2nd link photo you'll see some bits in the background and a red strip of rubber accross the bottom of the photo.These are made from black and white artworks with the original plan being to use them as models for casting badges,its old style rubber stamp making process materials.Anyways I've figured now the rubber will be good for bottom plates with feet and also small bits for knob tops)
End of update....previous
 In the photo you'll see 4 wooden models that then have a heat set modelling medium spread over them to make the prototype that goes to the foundry.The two top ones are right,the model,and left,the prototype.
 The bottom left is a model for a line of fuzzes I'll do to get some more cash together to fund this venture because I'm quickly running out of the money that was put aside to pay my Taxes...I didn't really want to do full fx because electronic design is not something I'm very good at  and don't feel completely comfortable mimicing someone elses stuff but end,in this case,should justify the means.Its a pity the photo of this one isn't so good but its going to be a nice enclosure with two levels with the top level polished alloy and the bottom levels painted orange.The eliptical area will have the word FUZZ cast into it with a small star above it and the knobs will be a green tint resin with glitter suspended in them.Should look a real treat.
  Tomorrow I'm going to enquire about have enclosures made with fibreglass reinforced with carbon fibre and hope they won't be too expensive as they'll be really light and so keep postage costs down.
  Just thought I'd let you all know how its going...
   
           Sean K,NZ.

[nelson]

Looks Really cool, Cant wait to see the finished Products.

[sean k]

Thanks Nelson,shoudn't be too long now.

[Regan]

Very cool Sean!
Regan

[Processaurus]

Its really impressive you're following through with you scheme of casting custom parts,  this is totally uncharted territory, at least for DIY pedalfolk.  Please do post some pictures of them when you get them cast, if you've got time.

PS  My favorite design is the one in the lower right corner of your picture, it looks like a rocket car from the Jetsons.

[sean k]

Thanks Guys,
                   I'm really enjoying the whole process of modelling in various substances and learning how some are quite good at some steps of the process while others are better at other stages.Its a steep learning curve and I really enjoy the risk involved in pushing my talents and ability to adapt to the new things I'm learning.Carbon fibre is 5 to 8 times more expensive than regular fibreglass but that still puts it in the ball park and may even be necessary to keep frieght costs down.
      One thing I've come up with recently is to put small flanges on the outside of the enclosures so they can be screwed onto pedal boards.I really wanna do stuff that works for the players and builders!

[MartyMart]

Those enclosures and "knob" drawings look fantastic !!
great work, I hope they turn out as good as they look now !!

Regards,
Marty.

PS: the "attach to the board" thing is a good idea, but if the flanges are
troublesome/look bad you can always use "bicycle chain" links to attach
the pedals, from around the bottom screws .
They just have to be fairly close to the outer edge of the enclosure
If you could source those "8" links and supply them in with the pedals, that would be great !!!
I wish others would do this ..... !

[RobertKeeley]

Howdy Sean!  Very impressed with your work!  I could use a tech of your ability!
rk

[sean k]

Howdy Bob,
                Is that just a wish type thing or are you after some outwork to be done.That is actually a part of my plan.I'd really like to play whatever part I can with small to medium scale boutique builders from initial design through to sending over prototypes you can take to your local foundry.
 Guaranteed one offs to keep the boutique builders on ground that'd be hard for mass producers to follow.
                                                 SK,NZ.

[troubledtom]

cool!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
peace,
      - tom :wink:

[sean k]

Update:All the enclosure models in the previous photo have gone to the foundry and I should see them the day after tomorrow...fresh new cast aluminium.
   When I get them I should have this one finished
http://photobucket.com/albums/y115/quickkiwi/?action=view&current=newbox.jpg

 So from this you can kinda see how much work goes into creating the prototype shell that goes to the foundry.Once the rough cast comes home I'll then get it primo with metal working tools and this will be the enclosure that goes back to the foundry for production.
  The funny thing is that no matter how good the finished casting model is the finish largely depends on how much work is done degassing the pouring and then poured metal.Ungassed needs filling and would be the cheapest I could sell them whereas a fully degassed pour would create casts for polishing and electroplating...but they wouldn't be as cheap.

   I also went and saw the fibreglass people today and found out the idea of using carbon fibre was way too expensive but regular fibreglass may work out just fine.Fibreglass with two layers of matt and using acrylic resin means I can do 10 or so at a time and keep the price right down.The only problem is sheilding them and this can either be accomplished using adhesive backed alloy foil or using some type of paint.At the moment I'm thinking about how to apply a base to a fibreglass top and I'm thinking about a cast alloy frame so three countersunk bolts could be used to join the two together.This way the frame would also be able to be screwed down to a pedal board and then the top reattached with the side mount screws.Also fibreglass allows pedals to be coloured,in the mix,so makes them easier on the eye straight off.I'll go and do a drawing to show you all what I mean.

[Clipped]

Sean -
Thanks for sharing. This is very interesting to see the process, so I hope you continue to update everyone.

Good luck to you!

Ron

[sean k]

No problem friends in virtual stompbox land.I see the whole thing as a commercial opportunity I can plunder for a few years but more importantly something that gives me a chance to design and fabricate in an area that has remained fairly static for a long time and has a lot of room for improvements of an ergonomic nature...Its a challenge and I'm learning heaps.
Like when I have these ideas and work as much as I can on paper...
http://photobucket.com/albums/y115/quickkiwi/?action=view&current=glassbox.jpg
then I have to find the materials that'll work as models in the actual crafting of a prototype but will also stand the rigours of any production process.I had three knobs,out of fifteen, break down in the molds as they are subjected to several thousand pounds of pressure and 130 degrees C in the making of the silicon molds.They were bullet types and I'm thinking that the small hole left in the top for a nail to centre the knob in the lathe which was just filled at the very top created enough space for them to fall in under the enormous pressure and can maybe be fixed by leaving the nail in there,albeit slightly under the surface.But I'm going over there,to the foundry now,to check out progress as they started the casting yesterday afternoon.
 Oh and if I ever get round to learning website building I'll put the whole process in there with the sales stuff.I've always found that if the whole process of making something is transparent then people try it themselves and some fail,they become more appreciative of the work involved,some succeed...and become competitors and keep you out of the stagnant pools of complacency.