Making An Amplifier Case From Raw Aluminum

I'm building a 4 channel amplifier and this is the chassis / case for it. Or at least most of it - I still have to make the front and back panels, but those are significantly easier.
I used thick aluminum for two reasons: first, I had a piece of it left over from a job I did years ago, so we can call it free material. The second reason is heat conduction. The case itself will act as one large heatsink helping to cool the amplifier.
And I guess a third reason would be that thick aluminum is a premium quality material to build with, unlike thin sheet metal.
The finished amplifier will be 17-1/2" wide x 15-1/2" deep and 3-1/5" tall.

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[IBuildIt]

I'm building a 4 channel amplifier and this is the chassis / case for it. Or at least most of it - I still have to make the front and back panels, but those are significantly easier.
I used thick aluminum for two reasons: first, I had a piece of it left over from a job I did years ago, so we can call it free material. The second reason is heat conduction. The case itself will act as one large heatsink helping to cool the amplifier.
And I guess a third reason would be that thick aluminum is a premium quality material to build with, unlike thin sheet metal.
The finished amplifier will be 17-1/2" wide x 15-1/2" deep and 3-1/5" tall.

[MandoFettOG]

I love seeing you fabricate with metal. You alway have a keen eye for design. Gives me ideas for my own projects

[danhorton]

I subbed to your channel years ago as I too am a wood enthusiast and maker. Never in my wildest dreams did I think you’d venture into amplifier and speaker making which are my first passion (well my daughters and then DIY audio). This is so awesome, there are so few channels that go into this.

[gvanvoor]

Looking great. I’ve never cut aluminium with wood tools yet but love the tips you gave should I ever need to. Cutting angle aluminium with a miter saw (even a “cold cut” one) requires respect of safety aspects as small cut offs have the annoying tendency to fly off at great speed if they catch on the teeth of the blade

[shogunai]

You have the absolute perfect balance of left and right brain man. You're like a craft artist, the way all these different skills just come to you with such precision & ease is pretty special tbh.

You've been a big inspiration to me. Though I don't have the skills, tools or experience you do, I've managed to transform my studio acoustics and aesthetics, along with building my studio desk from scratch, a massive case for my modular synth, and a bunch of other bits and bobs. I've picked up so many skills and tips from your channel for all my projects, so thank you John! Over the last few weeks I had been dreaming about building my own MIDI master keyboard with an Aluminum case, and once again you have come through with the inspiration & insight to get it done. Cheers, looking forward to seeing what you've got planned in the future!

[DEtchells]

I loved your concept for fastening the ribs by edge-screwing them. It’s a great idea that I’ve tucked away in my mind for future reference!

[leviharker]

Really enjoying this type of content I tend to flip back and forth between woodworking and electronics/DIY HiFi every 5 or 6 years, and I think I am about to flip back to DIY audio. Following this build very closely, I appreciate the effort you put into these.

[saintapoc]

that dado+screw technique was mind blowing in how simple yet effective it is - excellent work

[KyleMerl]

Clever idea for mounting the dividers. And that cnc pattern looks damn good.

[GregsGarage]

That looks so damn good John! I put a .007" micro bevel on the edges of all my holes on the CNC. It's amazing how much that little detail will dress up a hole (unsolicited tip there...) I also just use a spritz of wd40 when cutting. It keeps the tools cutting a nicer surface finish and it cleans up easily. I'm going to have to steal your route and fold technique. It looks like that worked really well.

[wileecoyoti]

Beautifully done! One thing that might be a good idea is to use a small rubber or foam pad on the aluminum piece holding down the caps: they do change size over time and wouldn't want them putting extra stress on the caps. Of course they might be springy enough as is.

Really really like that pattern you cut in the top, super classy!

[JimDockrellWatertone]

Pretty cool the way you figured that out. Interesting methods.

[murphymmc]

I have cut aluminum with woodworking blades and with a blade designed for aluminum. Everything you said is absolutely correct. I never thought of lubricating the blade, great tip. Working with aluminum is "galling". ;-)

[LeJimster]

Very impressive. Aluminum is easy to work with. But at the same time difficult to get a high quality finish with things like the ventilation cuts. I'm impressed to say the least. Enjoying the build as it takes me back to the kind of work I was doing as a kid.

[dew-drop]

Looks really great. I've liked all the case builds you've done on your channels throughout the years. I think it's funny that with relatively basic woodworking tools you're able to make stunning cases for audio equipment/pc's; whereas a channel like Linus Tech Tips has a shop with all the fancy tools and their stuff doesn't come out half as good as yours!

[vinylcabasse]

this is incredible craftsmanship across multiple areas of expertise. i woul love to do something like this myself one day.

[RumpusTime]

John, you’re incredible dude. I hope to hone my skills to this level someday.

[enewhuis]

I've a smaller project. I've been looking for box fab techniques to give a new home to some vintage Neve recording console components. Your presentation here is supurb and inspiring! I've been trying to come up with a way to build the box with six flat panels but maybe it is time for me to get a brake. Your result is solid.

[davidbailey]

All I can say is, Wow, very very nice…!

[MuchoBocho]

Impressive. Your techniques are brilliant.