Electric Boxcab

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Also made a short video of the mill cutting the 45° angle. The slots were cut first leaving a 1/32" square which was then cut at 45° angle.
The video shows how the angle is cut. The machine makes four passes. Each time the head drops .010" into the cut. It takes about 1 minute
to cut the angle on one piece. Stuff this small needs a delicate touch when cutting. The part actually looks more like a triangle then plain angle.
The parts are cut from the main piece and soldered onto a .020" thick brass sheet. They are then cut to size to fit in the hole on the boxcab.
The video is silent. There's only machine and background noise anyway.

I finished up the louvers on the first boxcab. Developed a process that worked good and got it done in a
couple of hours. Three more boxcab's to go. I'm going to go with a screen on the bottom three openings.


Nothing better to do on Christmas Eve Day than to update the site

12/24/2023



Working on making a rounded roof. The screens
have been installed in the bottom openings.

First some CAD work. After that the mill was put to work to
crank out a dozen or so parts, the last as accurate as the first.

The parts to make up the sub-roof (?). About a dozen end pieces and a strip .030"
thick by .057" wide. The strip will be trimmed to length and will fit in the .0315" slot.

Here is one sub-roof assembled. The purlins were a sung fit in the slots and required a little persuasion with a
hammer. The nice thing about that is I don't need to make a jig to hold everything together for soldering.

A nice snug fit.

Added a center piece to make stringers more ridgit. My helper making an adjustment.

I flattened a piece of solder so I could find out how wide to cut the roof section.

The outside stringers first needed be soldered on. Since the cab side is also brass I would probably
solder the stringers to the side of the cab no matter how careful I was. A piece of aluminum foil to
the rescue. I folded it over the side and it'll prevent the stringers from getting soldered to the sides.
The green arrows point to the outside stringers and the red arrows point to the aluminum foil.