Installing a detachable power cord

[slipperyfingers]

Hi,
I would like to install a IEC Chassis inlet such as the one here:

http://www.referenceaudiomods.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=FURU_AC_INLET&Category_Code=CONN&Product_Count=5


I'm wondering the best way to saw through an aluminum chassis? It already has a 1/2' hole where the cord passes through the chassis.

Thanks in advance,
-SF

[HCStraub]

There are a few options.
If it were mine, I would measure the IEC socket, then draw it out on the amp where you want to cut. Then use my flex shaft drehmel(non flex shaft will work but are harder to use) with a fiber cutoff wheel to cut the opening. This will leave a decent edge and cuts pretty quick.
You can also use a nibbler, but it won't look as nice.

[sysexguy]

I put one of those Furutech's in my D'Lite, btw, good choice on the screw mount version, the snap in type can be a pain when one doesn't have the exact punch required (ie dremel or nibbling).

BTW, the nibblers will destroy your finger tone for about 36 hours unless the chassis is paper thin.

Andy

[donnyjaguar]

There is a chassis punch for the IEC socket, but for a one-off a Dremel should work like a champ. Don't make the hole too big. Its a one way trip. You can get the IEC sockets with integral fuse holders, mains switch, and EMI filters. One of my builds is so-equipped.

[slipperyfingers]

There are a few options.
If it were mine, I would measure the IEC socket, then draw it out on the amp where you want to cut. Then use my flex shaft drehmel(non flex shaft will work but are harder to use) with a fiber cutoff wheel to cut the opening. This will leave a decent edge and cuts pretty quick.
You can also use a nibbler, but it won't look as nice.

Thanks, I did draw it out on the chassis, but didn't have a Dremel tool, so I found a 35 year old hack-saw blade sitting around and got started on the hole. I was able to get the longest flat side to the corners (with a nice hump in the middle). but then I thought about taking a smallish drill bit just to the inside of the mark. I went all around and drilled about eight holes, then took the hack saw and cleaned it up a bit, and finally went to a small flat file and got it very close. I kept trying the inlet for fit, and filed a little more until in went in perfectly. I'll post a pic tonight.


Thanks for the help/suggestions,
-SF

[jay42]

Nibbler is a safer approach and a good tool to have.

http://en.wikipedia.org/wiki/Nibbler

[slipperyfingers]

It actually came out better than I expected...given the crude tools I had to work with...I was pretty determined though :AOK I've had this amp for about five years now, and just love it. It's about time I got around to converting that darn power cord.


http://home.comcast.net/~billvh/images/tribal45.jpg

[Structo]

Right on!
Where there is a will there is a way!

[donnyjaguar]

Very nice!