The aluminum Swiss cheese of failure

[Onion Ring Modulator]

I've been building pedals pretty much non-stop for the past two years, especially during the pandemic, so I convinced myself that I just might be able to pull off a DIY drilling for the Aion Meatball clone.

It's all just a friggin' HAIR too far off to one side and the PCB doesn't fit. 

Normally I keep my rejects around for repurposing, but I think this is on its way to the recycle bin. 

[EBK]

It's all just a friggin' HAIR too far off to one side and the PCB doesn't fit. 

Usually in such circumstances, you can shave the board a tad or grind a bit of the inside of the box away. 

[idy]

I think the remark about shaving the pcb or inside of box is a joke?
Usually here we take a rat tail file and make all those nice little round holes into oblongs. On a bad day you need a big washer to cover the evidence... And there's always bondo.

[idy]

Oh and welcome to the forum. And the meatball is kind of a tough one that way....

[EBK]

I think the remark about shaving the pcb or inside of box is a joke?

Not a joke actually.  For one or two (maybe three) holes, I'd walk them over with a file as you mentioned.  But here, assuming every hole is off by the same amount and direction, I'd rather adjust the board/box.

[idy]

Point well taken. I look at the meatball PCB and see maybe 1/16" around the side before you start slicing a trace....I take that back; 1/16" and you've taken out both border and trace.

[davent]

I've been building pedals pretty much non-stop for the past two years, especially during the pandemic, so I convinced myself that I just might be able to pull off a DIY drilling for the Aion Meatball clone.

It's all just a friggin' HAIR too far off to one side and the PCB doesn't fit. 

Normally I keep my rejects around for repurposing, but I think this is on its way to the recycle bin. 

Save it for another project and use an opaque full faceplate to hide what you don't need in the way of holes.

[idy]

Sorry, I have "Meatsphere" PCBs... maybe the Aion has enough room to shave... I should have known from the layout. Tell us how you like it when its up and running!

[Rob Strand]

If you have too much to shave off the PCB you can shave small amounts of each of the other places mentioned.  It all adds up to buy space.

[deadastronaut]

flip it over and use the bottom plate as the top instead....fill the holes. 

[Steben]

100 inches of wire?

[Ben N]

Use it for a tube preamp, something with at least two 12a_7s. All the knobs you need, and all the ventilation.

[kraal]

Hi,

If you have a Dremel or can borrow one, Use a dremel with a grinding stone accessory #952 (or eventually #932, or #8153 if you can't find #952), or even better a #9903 (tungstencarbide cutter) on the insides of the enclosure.

The #952 costs 8 CHF (less than 9 USD) and the #9903 costs 18 CHF (20 USD). If you really need a "hair" more space, it will take you a few seconds to fix your problem.
I have a #9903 for years now and use it qute a lot.

(Note: do not forget to put on safety glasses and a mask to avoid losing an eye or inhaling aluminium dust in the process)

[anotherjim]

Elongate the holes with a half-round file. Get some big washers to cover any gaps if necessary.
Or - make a new top panel that with work as an overlay on the enclosure. Chop out as much of the original top as you need to, it will be hidden by the overlay. But if it's only a "hair" off then the holy elongation will do it.

[Phend]

Rat tail the holes and JB Weld any gaps if required else use washers as mentioned.

[soggybag]

If the PCB fits in the box and the holes are off a bit to the left, right, up, or down get yourself a round file and reamer. I do this all the time. Yesterday in fact!




The two holes ont he outside of the second row needed to come in by a millimeter or two. I just filed it with a file and round the home out with the reamer. The washer is enough to cover it.

[AS74]

Sorry if this has been covered but what do you use for the graphics?

Thanks

[duck_arse]

my oft needed method is to drill undersize, then measure for missplacement. then file in the needed direction before reamering to right size. but, undersize to start .....

[davent]

Pile of assumption for this... but when using pcb mounted pots mount them in the enclosure or matching drilled workboard and then match the pot leads to the pcb bending where necessary, once all the leads match/fit the pcb only then get the iron out and solder them.

If it's not a crazy number of out of alignment you could remove them from the pcb and tweak the leads until thy fit the hole and reach the pcb.

[ElectricDruid]

I've been building pedals pretty much non-stop for the past two years, especially during the pandemic, so I convinced myself that I just might be able to pull off a DIY drilling for the Aion Meatball clone.

It's all just a friggin' HAIR too far off to one side and the PCB doesn't fit. 

Normally I keep my rejects around for repurposing, but I think this is on its way to the recycle bin. 

Yep, fair play for the brutal honesty.

I think you *could* mess about for hours trying to save the box as suggested by some of the other posters, but I think you're right and it's easier to accept the losses and start again and do it right the second time. We learn by experience, and sometimes (ok, mostly) that means that the "mark 1" version gets slung in a box never to be seen again. C'mon, people! Let's be honest! Haven't we all got a HUGE box of prototypes that sort-of work but were superseded by the version that we actually show the world?!?

I know I do. Most of my projects are on Rev.4 or so before they ever see the light of day! If you get this right on the second go, I'll be impressed!

So...yeah...it's not a aluminium Swiss cheese of failure. It's an aluminium Swiss cheese of early testing, leading to an altogether better final aluminium pedal of success.