Ran into problem.. Need recommendations!!

[Govmnt_Lacky]

So, I decided to etch, populate, and finish a board that was supposed to be designed to fit into a 1590BB enclosure with board mounted everything. Just went to "slide" it into the enclosure and...... it wont fit!  YES... I know it was a rookie mistake but... here I am! 

I have cut the board as close to the traces as possible without damaging the circuit. It will fit inside the box however, it is nowhere near small enough to rest down to the face of the BB in order for a proper fit.

It looks like the only way to salvage this work is to find an enclosure that is slightly larger than the 1590BB. I need another 1-2mm on the long sides of the BB for the PCB to fit properly. The short sides could do with another 1mm on each edge but I think I can make do.

Can anyone recommend an enclosure or a solution? This has board mounted jacks and I would like to keep it that way so keep that in mind.

Thanks 

[pappasmurfsharem]

any way to dremel or sand the insides of the enclosure enough?

granted even if it was close enough to do so, that's quite the task

What about a 1590BB from other sources? Most of the clone boxes vary by small amounts.

Where did you get yours from?

[rousejeremy]

The 125B is a little bit bigger than a 1590B, maybe there's a BB equivalent?

[Govmnt_Lacky]

What about a 1590BB from other sources? Most of the clone boxes vary by small amounts.

Where did you get yours from?

The enclosure I am working with is a true Hammond 1590BB

After looking at various enclosure sources, it looks like my only hope is to possibly find an enclosure that it a bit out of spec 

[pappasmurfsharem]

What about a 1590BB from other sources? Most of the clone boxes vary by small amounts.

Where did you get yours from?

The enclosure I am working with is a true Hammond 1590BB

After looking at various enclosure sources, it looks like my only hope is to possibly find an enclosure that it a bit out of spec 

sadness =(

[rousejeremy]

How about a 1790NS?

[hammerheadmusicman]

You could trim it down enough to fit. Then patch across the tracks that are broken. Messy, I know. But, it'd get it to fit.

George

[Govmnt_Lacky]

How about a 1790NS?

That one is too big. The BB measures 3.68in (94mm) on the short sides. This is where I need a bit more room. Something with 96-98mm would be perfect.

You could trim it down enough to fit. Then patch across the tracks that are broken. Messy, I know. But, it'd get it to fit.

The traces on the board run VERY close to the edges. Any more triming and I would lose them all together 

[stallik]

Given that the boxes are cast, I wouldn't have thought that an out of spec box would not vary enough to give you the dimensions you require   
I made exactly the same mistake some time ago because I did not take into account the slope within the box  (and I've never been great at measurements ) but was able, just, to trim the board. It ended up fitting and worked but was such a mess that I eventually bit the bullet and made another board 
I hope you find another box...

[rousejeremy]

Time to get a bending brake and start making your own enclosures. And then selling them to us. 

[R.G.]

Cut off the traces as needed to make it fit, then patch the traces back with wires. Make sure that the edges where the traces were cut away don't short.

Neatness counts on this one.

[Govmnt_Lacky]

Cut off the traces as needed to make it fit, then patch the traces back with wires. Make sure that the edges where the traces were cut away don't short.

Neatness counts on this one.

Unfortunately, it is a bit more involved than that.

The layout placed quite a bit of the component pads close to the edges as well. So much so that cutting the edges more than they already are will cut away a lot of component pads as well. Not only would it mean cutting traces away but it would also mean that components would need to be relocated and patched.

It would get REALLY ugly! 

I could always just put it into a larger enclosure and just wire the jacks offboard but I was really hoping to avoid that.

[joegagan]

I would use  a saw, notch the enclosure, then build a bump out panel with plastic made to look intentionally thick as part of the design. I keep lots of sheet abs around for fabbing, different thicknesses. Get creative!
Maybe a batt door that takes up the entire side, or a jack mounting plate , etc

[davent]

Have you checked on the dimensions of Pedalenclosures Prism 1. I had no luck finding them so you may need to contact Mike directly, does look like a possiblity.

http://www.pedalenclosures.com/

1590KK 4.92x4.92x2.1, kinda' deep
1590XX 5.72x4.77x1.3 ***
1590J  5.71x3.74x1.77 kinda' deep

[tubegeek]

From another thread:

did your old man ever say "when yr only tool  is a hammer, pretty soon every problem looks like a nail"?

Mine said, "There is a proper tool for every job, and that tool is a hammer."

Kidding aside, would it be possible to angle the board and still make the parts that go through the face of the enclosure work?

Other than that, I'd go with either a custom-bent steel framing member box a la R. G., or a new PCB from scratch.

[Jdansti]

I don't know if this would give you enough room, but I've heard of motor guts being inserted into their cases this way:  heat up the enlclosure to get it to expand a little and carefully insert the PCB. Wear some good oven mitts!  You might want to thin the walls with a Dremel tool first.

[CodeMonk]

I don't know if this would give you enough room, but I've heard of motor guts being inserted into their cases this way:  heat up the enlclosure to get it to expand a little and carefully insert the PCB. Wear some good oven mitts!  You might want to thin the walls with a Dremel tool first.

I used to have to do that to insert things like to crankcase bearings in a motor.
But the expansion is pretty minor.

[nomorebetts]

Oh boy is my face red  

I believe Greg is referring to a layout I did and he has ended up being the first builder/guinea pig.  Otherwise its an amazing coincidence!

What about this one? 119 x 93.5 x 34mm
http://www.jaycar.com.au/productView.asp?ID=HB5067

Or this one; 120 X 94.5 X 34mm
http://www.pedalpartsaustralia.com/index.php?main_page=product_info&cPath=3&products_id=6

These are probably outside dimensions... need to find a data sheet.

But I think I have one of the Jaycar ones laying around so can print the layout and check the fit.

[Govmnt_Lacky]

Oh boy is my face red  

I believe Greg is referring to a layout I did and he has ended up being the first builder/guinea pig.  Otherwise its an amazing coincidence!

What about this one? 119 x 93.5 x 34mm
http://www.jaycar.com.au/productView.asp?ID=HB5067

Or this one; 120 X 94.5 X 34mm
http://www.pedalpartsaustralia.com/index.php?main_page=product_info&cPath=3&products_id=6

These are probably outside dimensions... need to find a data sheet.

But I think I have one of the Jaycar ones laying around so can print the layout and check the fit.

You are correct sir! I am trying to fit the original rotary switch version into an enclosure. 

I think I am going to need at least 97-98mm in the short sides for it to work.

Unfortunately, I have a bit bigger problem right now. Plugged it in last night and got some horrendous noise!  Time for a debug (gonna be a while as I have other projects ahead of this one)

[GGBB]

Greg - the Eddystone 29830PSLA is ever so slightly bigger than the 1590BB.  It's only 1mm wider overall but according to the spec sheets inside width at the face it is 2.42mm greater.  The challenge will be finding one in NA or that's reasonably priced after shipping.

http://www.hammondmfg.com/pdf/1590BB.pdf
http://www.hammondmfg.com/pdf/29830PSLA.pdf

Other than those two. the 1550M is a few mm bigger overall.

http://www.hammondmfg.com/pdf/1550M.pdf