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Podunk Steam

Member For 4 Years
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I'm attempting a new stupid human trick, Dual 18650s in a CNCed 1590A box powering a DNA 200. The most stupid part of this is posting it before its done, bound to fail now!
And here we go.
IMG_20150918_195155_zpsuqqsap8y.jpg

USB hole check!
1590Atestfit_zpsgrusd7g2.gif

Battery holder, with battery and circuit board fits, check!
 

hogheadv

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I could be wrong but doesn't the DNA 200 require triple 18560's or a lipo pack?
 

f1r3b1rd

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it'll run 133w with 2, 18650s
 

Podunk Steam

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I can't see myself using 200 watts although I could do a Lipo in one of these boxes. One build aspect that will be seen, I'm not able to do for a 200 watt version being I'm not CNC equipped. This will make more sense later in the build.
Stay tuned! ;)
 

DevAuto

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This looks pretty awesome so far. Can't wait to see how it works out for you!
 

Podunk Steam

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Thanks!
My partner doesn't know how to take this one, it's my first Hammonds style build, really frickin boxy box mod! I'm going to have to take a rounding mill to at least four edges I think, may be a little more comfortable in the hand that way.
 

Podunk Steam

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A few more steps done although it looks like the door will be worked a little more.
What used to be the back of the box is now the front.
IMG_20150923_174329_zpshqcdecak.jpg

The door which is now the back. I might set that 1 in a little deeper when I go back in the shop again.
IMG_20150923_181824_zpsbsvctxbj.jpg

Had to even up things being I didn't want to mill through the USBs hole, space is at a premium.
IMG_20150923_184642_zpsfjeslgjz.jpg

It worked out for a location for a little label. Being the mod does 133 watts that's what is going to be put on it, the 3s will be in the bar button controlling up and down features.
IMG_20150923_204439_zpswalrhdtl.jpg

Clean up the display and milled edges and this will just about be ready for coatings.
 

munchy_cool

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nice...would love to see a completed build.
 

Podunk Steam

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Moving along at the usual tectonic speed here, I've been told speed kills so this dude abides!
The latest step forward has been the coating of the battery holder, just one side with epoxy to hold the print filament together while being drilled eventually. The back side will be coated as well as having an aluminum wrap that will serve multiple purposes.
IMG_20150925_130851_zps9kog6r03.jpg

What he said!
 

Podunk Steam

Member For 4 Years
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I just took a picture of this for another forum so I'll update the progress here too.

This is a tool to make a part for better electrical connection in the 133, the mod I'm building.

It's for forming a sheet of copper to make contact with the bottom of the 510 connector.
IMG_20150929_173946_zpsw8y5llk6.jpg

And my first run at making the plate although I haven't done the math with this thickness of copper yet. If I need thicker I can drill the center hole larger in the tool I made and a larger hole in the copper initially should help with the tearing a bit although it will never be seen and serve the purpose intended.
IMG_20150929_185242_zpszsowakdq.jpg

Oops! Bad example, the copper plate will fit on the 510 the other direction. LOL!
 
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DevAuto

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Looking good so far! Loving the pics and can't wait to see the finished version!
 

Podunk Steam

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Thanks, really should keep your wick moist so here's where I'm going.

Wimpy say hello to Beefy, Beefy say goodbye to Wimpy.
IMG_20150930_214158_zpsdmnbxnji.jpg
 
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Podunk Steam

Member For 4 Years
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Mmmmm, Beefy
I'm not sure I could have done any better, I just have to get the length of the copper cylinder correct and it will press fit onto the base of the 510 while tightening the 510s locking nut. :)
IMG_20150930_234119_zpsq9hkmqij.jpg

Edited for another pic
IMG_20150930_235209_zpswymemhpk.jpg

Cylinder milled to spec one more step with this part as it serves a couple purposes.
IMG_20151001_021848_904_zpskqwmn3cl.jpg

Should work out really well.
IMG_20151001_023707_zpsanazejfs.jpg
 
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Podunk Steam

Member For 4 Years
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Oh damn, I didn't post up the 510 connector yet. It has a custom milled copper center pin, the deck has been milled down flat and thin and there is an extra strong spring in the bored out plastic part for the spring.
There is a reason behind the thin deck and the copper plate I made. There should be less resistance in the negative going back to the circuit board because of the thin deck and the copper press fitting to the base of the 510 connector. This will all be seen for what it may really serve once hooked up to EScribe.
IMG_20150904_035641_zps19vtqzln.jpg

IMG_20150904_034224_zpspurxmf1b.jpg
 

Podunk Steam

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Thanks Jasen! I hope to be able to make the exterior purrdy too. :)
The trickiest part to fab still has to be build and its tolerances have to be pretty tight or the lid won't close flush. The buttons first coating is a process I haven't done yet, electroplating, but the powder coat in the 3s on the bar button I think shouldn't be an issue. Beyond that it's just some tricky masking and powder coating on the exterior. The area outside the milled areas on the exterior are still in debate between me, myself and I, we just can't come to terms. Raw polished with a clear coat, black powder coated or jeweling with a clear coat, jeweling is often done on the bolts of rifles.
 

DevAuto

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Thanks Jasen! I hope to be able to make the exterior purrdy too. :)
The trickiest part to fab still has to be build and its tolerances have to be pretty tight or the lid won't close flush. The buttons first coating is a process I haven't done yet, electroplating, but the powder coat in the 3s on the bar button I think shouldn't be an issue. Beyond that it's just some tricky masking and powder coating on the exterior. The area outside the milled areas on the exterior are still in debate between me, myself and I, we just can't come to terms. Raw polished with a clear coat, black powder coated or jeweling with a clear coat, jeweling is often done on the bolts of rifles.
You said "rifles" ... I vote jeweling ... :D
 

Podunk Steam

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Thanks! One vote jeweling, CHECK!

My only concerns are potentially loosing the refracted light created by the jeweling with a clear coat. As well as Aluminum not being as hard a metal as utilized in firearms production and it may not hold the jeweling all that well, I mean for an extended period of time. The upside is being somewhat maintainable as I could redo the jeweling down the road if I didn't clear coat it. This may work into a test prior to the application if I go the jeweling direction.
Me myself and I are still bantering this area of the exterior. The worst part is this type of bantering usually takes longer than the building of anything I've done and progress really slows to a tectonic crawl.
 

DevAuto

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LOL ... Despite the tectonic speed, I am quite impressed with the progression on the project. It is stunning so far, and I wish I had the time, knowledge, skills and abilities to build such an impressive mod myself.
 

Podunk Steam

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Thank you for the kind words! I'm really hoping I manage to pull this one off as I've had it pictured in my mind.
 

DevAuto

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Well, if you don't, I might just know a guy interested in buying the "failed" attempt ... LOL!

Seriously though, while I don't have the artist's vision (I can't read minds), I really think that it will be impressive regardless of whether or not it is a perfect match for your vision.
 

Jasen

Member For 5 Years
I like the idea of jeweling the inside only.

Just what you need, another voice in your head.
 

Jasen

Member For 5 Years
I'm always in Podunks head, rattling things around, oilin the gears, and sometimes just poking that grey mushy thing just to see what happens.
 

Podunk Steam

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Well, if you don't, I might just know a guy interested in buying the "failed" attempt ... LOL!
Might have to take payment in hats, you tend to swell a guys head beyond his usual hat size. ;)

Jasen, you playing with marbles again? The big aggies are shooters man, not the ball bearings!

Edit: Almost forgot the pic. We'll be hashing this out in the process of the rest of the parts to be made. On to button fab with me.
IMG_20151001_211121_zpsaagqso68.jpg

Between not having yet acquired the taste for milling coolant on my fritos and my calipers trying to lie to me I think it's best I pack it in for the evening.
IMG_20151001_231249_zpsq2qczico.jpg
 
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Jasen

Member For 5 Years
Sorry, just the pain meds talkin. Go to see the Dr. friday and hopefully get released to return to work.
 

Podunk Steam

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All's well man, no worries. I may soon have a few more important priorities myself, like a real job. The background check got stalled somehow so I'm not playing in the big machine shop yet.
 

Robert B

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Oh damn, I didn't post up the 510 connector yet. It has a custom milled copper center pin, the deck has been milled down flat and thin and there is an extra strong spring in the bored out plastic part for the spring.

Now that the pad is paper thin, does an atty still screw down and sit flush on it?
 

Podunk Steam

Member For 4 Years
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Might be about sheets thick, LOL! Yes atomizers do sit flush and once backed up by the box it won't go anywhere, or at least that's the theory anyway.

Snapped a pic for you.
IMG_20151002_001948_zpsylv3plt8.jpg
 

Robert B

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Might be about sheets thick, LOL! Yes atomizers do sit flush and once backed up by the box it won't go anywhere, or at least that's the theory anyway.

Snapped a pic for you.

Looks very nice. The few boxes I've built, I put a very small drop of epoxy under the pad to keep it from spinning
 

Podunk Steam

Member For 4 Years
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Thanks!
I have to do something similar in a few areas, not all so much for adhesion of the parts but as to help ward against galvanic response. I think by the time I'm done I'll have have four or five dissimilar metals involved. My thought has been some extra conductive head gasket sealant I have out in the garage and liquid tape left to dry before final assembly in a few places.

Edit: Sorry I guess the proper terminology these days is "galvanic reaction". If the English language isn't confusing enough they think they have to mod it all the time!

This 510 by the looks of what I have so far may never be able to be taken out of the box again so some epoxy under the deck may not hurt. When the copper slides over the base of the 510 it will expand and lock up against the aluminum of the box most likely. Thanks again.
 
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Podunk Steam

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IMG_20151001_231249_zpsq2qczico.jpg

This crooked thing's going to haunt me if I don't make another run at it, round two coming up.
 

DevAuto

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IMG_20151001_231249_zpsq2qczico.jpg

This crooked thing's going to haunt me if I don't make another run at it, round two coming up.
The question is ... Will it haunt you from a performance perspective or a perfectionist one? ;)
 

Podunk Steam

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That would be the old perfectionist crew bouncing around in the bellfree, no performance issues at all. One of these days these minones may just come to terms over a bowl in the piece pipe but than knowing me myself and I they'd just Bogart it. They did manage to come to terms over the exterior design, it was an Easy Rider Jack nik nik Nickelson argument the stenographer napped through or Id post up the details, those guys are nuts!
 

DevAuto

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That would be the old perfectionist crew bouncing around in the bellfree, no performance issues at all. One of these days these minones may just come to terms over a bowl in the piece pipe but than knowing me myself and I they'd just Bogart it. They did manage to come to terms over the exterior design, it was an Easy Rider Jack nik nik Nickelson argument the stenographer napped through or Id post up the details, those guys are nuts!
LOL! I feel your pain. I have just such a crew here as well. They do tend to make things harder than they should be sometimes.
 

Podunk Steam

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Oh yeah but than every once in a while they tend to pull it together and geterdone, a thin strip of scotch tape was the ticket to happiest, cheap price to pay for a little taste of sanity.
Way more better this time and something I can live with. I got a better start on this one by cleaning up the brass first so I don't have to question the adhesion of the electroplating in the 3s. Houston we're good for launch, ur mill anyway.
IMG_20151003_222636_zpsu8ef0mk9.jpg
 

Podunk Steam

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Why thank you kind sir, I do believe they shall suffice.
IMG_20151003_234152_zps2razfj4z.jpg

IMG_20151003_234024_zpstkocxnmd.jpg

Now for the ever so not so fun hand work to round the ends. The retaining section on the back will be the last part of the milling process just to have the thickness just right.
 

Jasen

Member For 5 Years
The last picture brings it all into the light. Now I see where your headed and I like it.
As expected, this will be the hammod build all others will aspire to be.
 

Podunk Steam

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Oh I don't know, that would be kinda subjective and there's always someone better out there but thank you!
 
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Podunk Steam

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New job has taken priority although I'll be accustom to the new schedule soon enough. Been doing the antsie new employee thing, wake up at 2 in the morning can't back to sleep, show up an hour early for work, first good nights sleep since I started last night, might be melting into the groove.
 

DevAuto

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New job has taken priority although I'll be accustom to the new schedule soon enough. Been doing the antsie new employee thing, wake up at 2 in the morning can't back to sleep, show up an hour early for work, first good nights sleep since I started last night, might be melting into the groove.
Congrats on the new job! Hopefully the schedule adjustment is over and you will continue to get a good night's sleep!
 

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