How would you do this?

dandos23 · 20 Feb 2011 at 12:10

In an attempt to keep it simple, I have a 1.2mm x 222mm x 623mm (H x W x D) piece of rectangular metal.

There are 2 200mm holes in it at the moment and I need it to look like one piece of metal that is also strong.

How would you fill in the holes?

bigjimmyauk · 20 Feb 2011 at 12:20

If you talking as in making it 1 piece of solid metal again your wasting your time, too much hard work you'd have to find some metal disc roughly the same diameter as the voids and weld them in then grind and smooth it all back. it would then need priming,undercoating and finished otherwise it would look rather rubbish

Coldzero · 20 Feb 2011 at 12:26

Would probably be just as cheap and a lot more time effective to source a new piece of metal.

dandos23 · 20 Feb 2011 at 13:04

I was thinking the same thing but sourcing a new piece is not as easy as it sounds as there are a few bends in the metal as well.

bigjimmyauk · 20 Feb 2011 at 13:07

dandos23 said:
I was thinking the same thing but sourcing a new piece is not as easy as it sounds as there are a few bends in the metal as well.

could you post up a pic of said piece of metal

~>Dg<~ · 20 Feb 2011 at 13:11

no little metal fabricators near you ?

dandos23 · 20 Feb 2011 at 13:17

bigjimmyauk said:
could you post up a pic of said piece of metal

From the top

from the side

I need to fill in the 2 large holes to be able to cut
1 new hole of a slightly different size and in a slightly different place.

dandos23 · 20 Feb 2011 at 13:19

~>Dg<~ said:
no little metal fabricators near you ?

I am speaking to one over email at the moment but everyone I speak to says to just rivet a piece of metal on top or underneath which will look rubbish!

bigjimmyauk · 20 Feb 2011 at 13:50

dandos23 said:
From the top

from the side

I need to fill in the 2 large holes to be able to cut
1 new hole of a slightly different size and in a slightly different place.

No the only way to do that would be to get some discs cut the same size as the holes minus 0.25mm then weld it into place, grind it back and then sand it smooth.

Gonna be a ball ache to do yourself but a decent metal fab should be able to do it in an hour or so to a finish ready for painting.

The only other method is to use liquid bodywork metal for cars the stuff you mix into a paste, then build layers up inside the holes. Only problem tho is that it will be very weak compared to welding new pieces in there.

dandos23 · 20 Feb 2011 at 14:00

bigjimmyauk said:
The only other method is to use liquid bodywork metal for cars the stuff you mix into a paste, then build layers up inside the holes. Only problem tho is that it will be very weak compared to welding new pieces in there.

What about a complete new piece of metal then which I can then send for powder coating later. How long would that take roughly?

Thanks for the help guys.

bigjimmyauk · 20 Feb 2011 at 14:05

dandos23 said:
What about a complete new piece of metal then which I can then send for powder coating later. How long would that take roughly?

Thanks for the help guys.

You mean for a fabricator to make up for you, or to do yourself?

a fab could probably replicate that piece in around 1-2 hours it's not something i'd attemp at home tho without the proper equipment otherwise the bends in the edges will not end up being right more than likely.

dandos23 · 20 Feb 2011 at 17:03

I mean for a fabricator to make it for me. I might posses the knowledge to do it but don't have the equipment (probably not the knowledge either).

Don't suppose you have any idea what something like that would cost?

bigjimmyauk · 20 Feb 2011 at 17:26

dandos23 said:
I mean for a fabricator to make it for me. I might posses the knowledge to do it but don't have the equipment (probably not the knowledge either).

Don't suppose you have any idea what something like that would cost?

As a one off piece it would probably be about £100+

I mean if my old company would do this it would be say

15 minutes of CAD time £15
15 minutes of CNC time around £60 (usually half hour minimum prices due to set-up time)
Material costs £5-£10
Then FAB time to put the bends in place and finish up the edges (30 minutes to 1 hour) thats around another £30

This is all just guestimate from prices a year or so ago but should be along those lines .

If you could get the discs to fill the holes you could probably get a welder to weld them into place for £20 Check local add for mobile welders or find a local factory that does welding most people will be willing to do a little work in their dinner break for £20.

dandos23 · 20 Feb 2011 at 17:36

Thanks bigjimmyauk
I will try and find a local welder to do it, then I just need to send it off for powder coating.

This should be an interesting build.

bigjimmyauk · 20 Feb 2011 at 17:54

dandos23 said:
Thanks bigjimmyauk
I will try and find a local welder to do it, then I just need to send it off for powder coating.

This should be an interesting build.

the discs ideally need to fit within 0.5 mm of the diameter or the welder will have grief doing it. also fill any bumps etc yourself and smooth it off well ready for the powder coat.

ALSO please keep us informed what happened etc etc i hate when people never update a thread.

dandos23 · 20 Feb 2011 at 18:00

I have a build log planned for my first ever water cooling rig so will be putting everything in there. I am still in the stages of getting it all organised as to where it will all be going at the moment.

Thanks again.

RobFromTheWood · 21 Feb 2011 at 21:34

i would make a flat sheet the same size as the top and screw or glue to the top
assuming that it can only be seen from the top?

piggin · 21 Feb 2011 at 22:08

I would cut a new plate for the top (about 1mm smaller than the original size) & fix it in place.

Then drill the corners & attach the panel with counter sunk pop rivets. Fill the gaps/holes with chemical metal filler.

If you use body filler, you will not be able to powder coat the panel but metal filler will work without problems.

As for welding, is the panel steel or aluminium ?

If its aluminium, then you will have to get new sections TIG welded into place.
This will cause heat distortion.

dandos23 · 21 Feb 2011 at 22:52

piggin said:
I would cut a new plate for the top (about 1mm smaller than the original size) & fix it in place.

Then drill the corners & attach the panel with counter sunk pop rivets. Fill the gaps/holes with chemical metal filler.

If you use body filler, you will not be able to powder coat the panel but metal filler will work without problems.

As for welding, is the panel steel or aluminium ?

If its aluminium, then you will have to get new sections TIG welded into place.
This will cause heat distortion.

It is steel, so heat distortion should not be a problem.

The reason I tried to keep the OP simple was because whenever I try to explain it everyone just give me the same response as to solving this. Now that I have quite a good idea as to what I will need to do I suppose that I can explain it a bit more.

It is the top piece of metal from an NZXT Phantom case. There is a plastic top that fits on to this that has to line up with another plastic bit on the front of the case. If I put another piece of metal on top then it will not line up so I cant do that. I also have very limited space underneath (about -6mm) so dont really want to lose any space from there either.

That is why I am trying to find the best way to fill the holes without having to attach another piece of metal on top or underneath.

Considering this will be my first proper build and first time water cooling I seem to have chosen quite a complicated one.

piggin · 21 Feb 2011 at 23:02

Are these cases readily available.
If they are, I would consider cutting my losses & getting a new one.
Unless you are going to do the work yourself, someone will take £100 of you to fix the holes. :mad: