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?

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.

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!

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.

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?

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.

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.

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.

dandos23 · 21 Feb 2011 at 23:29

piggin said:
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.

I know it will not be cheap, but I like the case and though it would be a good learning curve to give it a go.

I also have a few other ideas that might work but will save them for the build.