On Tue, 18 Oct 2005 13:54:15 -0500, Bill Schwab
wrote:

Hello all,

I have two projects that are loosely related. One requires a tray that
is almost certainly a "build" and the other needs a box of specific
dimensions, and is a "build or buy" depending on what sizes are
available commercially.

Let's start with the tray. We have steel slotted angle on hand, and I
propose to use it to create an L-shaped structure that has some adapters
to support a printer, connecting to existing tapped holes to one side
and "reaching down" to another shelf on the other end. That shelf is
plastic-laminated particle board, so a couple of wood screws will make a
good connection.

Are there metal analogs to wood joinery techniques? I am learning how
to assemble pieces of wood with little more than clever cutting and glue
(see keywords such as mortise, tenon, rabbet, dado). Given the right
keywords, I am happy to read how do similar "correct" work with metal.

As an example, what would be the best way to joing the slotted angle
pieces at a corners of the tray? They can simply sit one on top of
other. I could miter them at 45 degrees and add something, or create
something like a wood lap joint (mill each to half thickness and then
bolt them in a couple of spots??). The simple overlap would work well
for the tray because the uneven surface that results will not be a
problem: the printer will be held by "feet" on rails or something.
Better ideas are most welcome.

Now for the box. If I can buy one of the correct size, then great.
Otherwise, I start thinking of aluminum, with mitered (at the corners)
extruded pieces along the edges and at strategic places along the length
of the edges (for holding the junk inside the box), with sheet metal
walls that carry the shear ("stiffen" the box).

Comments or better ideas? I want it simple, strong, easy to build,
cheap of courseg, and it potentially needs to be a certain size. The
size will hopefully be worked out shortly. I am starting to make full
scale models of the important pieces (single board computer, power
supply, safety equipment, etc.) and will look at various ways to package
them. The stuff needs to fit in the box, and the box needs to fit in a
space with fixed dimensions; hopefully it will end up being quite
forgiving. If all goes well, I will end up merely adding an externally
accessible bay to a commercially made box.

Bill

New keyword: " weld". There is no analog in woodworking. "Glue"
works by adhesion, a weld works by fusing the metal into one piece in
the weld region.