Project Boxes with Flat Edges (no slopes)

[Gummy Bare]

I'm really looking for some project boxes for a box mod build that do not have that angle/slope on the sides of the box. I know the most popular boxes are the Hammond 1590B & 1590G; and those sizes are around perfect for a few projects I want to do.... But I just can't get over the slope on the edges of them.

You guys know exactly what I'm talking about. They have this 2 degree or so slope on the edges that make the box sit on the table crooked and also make the atty that attached to it sit at and angle/crooked. I know you can kinda sand them down to get rid of some of the angle, but then you run into sanding right into the counter sunk screw holes for the cover.

So I'm looking for some alternatives; some project boxes that actually have level edges to one another.... Like, 90 degree edges with no sloping angles.

Please someone shoot me into the right place. I can't seem to find what I'm looking for.

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[rhelton]

The hammond box's are great. Order a plain one with no paint and get you some sandpaper, one grit, one finish and 2x4 for a block and start sanding. were working with cast aluminum it is soft and you can sand it down to where you want in 15 min. Paint it up and your off and runnin,.

 

[Quigsworth]

I'm really looking for some project boxes for a box mod build that do not have that angle/slope on the sides of the box. I know the most popular boxes are the Hammond 1590B & 1590G; and those sizes are around perfect for a few projects I want to do.... But I just can't get over the slope on the edges of them.

You guys know exactly what I'm talking about. They have this 2 degree or so slope on the edges that make the box sit on the table crooked and also make the atty that attached to it sit at and angle/crooked. I know you can kinda sand them down to get rid of some of the angle, but then you run into sanding right into the counter sunk screw holes for the cover.

So I'm looking for some alternatives; some project boxes that actually have level edges to one another.... Like, 90 degree edges with no sloping angles.

Please someone shoot me into the right place. I can't seem to find what I'm looking for.

:: sent from android with tapatalk ::

I feel your pain Gummy and was one of the big reasons why I bought a decent quality bench disc sander (that and to lp my Grands)... problem is, you can't make a mould with straight 90° sides... you'd never get it out of the mould... you'd be suprised how little it takes to true up the bottom and top (I leave the sides meh...)... Plus you have to clean those edges up anyway of all the flashing.

I'm just glad I'm not the only one with OCD [emoji1]

 

[Gummy Bare]

The hammond box's are great. Order a plain one with no paint and get you some sandpaper, one grit, one finish and 2x4 for a block and start sanding. were working with cast aluminum it is soft and you can sand it down to where you want in 15 min. Paint it up and your off and runnin,.

That was the plan. I got 3 Hammond plain aluminum boxes right now. I've also watched a few videos of people doing a little sanding to clean them up and get the cover/door seem all nice. But, I've also asked for flat boxes and expressed my concern to getting the edges flat wile in other box mod groups. I was getting mixed answers if it was possible... One guy showed me his sanding to get the edges flat and it went super far into the counter sunk screw holes and still wasn't truly flat. I hear it's not necessary "practically" possible.

I hope it is possible and doesn't come with any extra issues (like sanding threw the metal, or threw the screw holes, or any other list of issues). But yet I see sooooo many box mods made by people with far more gear, actual shops, massive amounts of knowledge compared to me, and even "pro" ones being sold on vape sites that ALL have the damn crooked edges on them.

So it makes me wonder, if it's so easy to do and absolutely possible.... Why are so many Hammond (and other project boxes) box mods out there with the crooked edges and leaning attys hanging off of them? I just don't get it.

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[Gummy Bare]

I feel your pain Gummy and was one of the big reasons why I bought a decent quality bench disc sander (that and to lp my Grands)... problem is, you can't make a mould with straight 90° sides... you'd never get it out of the mould... you'd be suprised how little it takes to true up the bottom and top (I leave the sides meh...)... Plus you have to clean those edges up anyway of all the flashing.

I'm just glad I'm not the only one with OCD [emoji1]

Yea man, your not the only one it bugs. I got turrets syndrome, which shares some very OCD like qualitys.... And the crooked boxes drive me nuts!

I also did read that the angle was to help get the mold out.... I've actually been emailing and talking with Hammond and many other stomp box and project box companies trying to find answers and what I'm looking for. The reason you mentioned always came up.

Would you be able to post some pictures of a Hammond box you've sanded completely flat on all edges? Like all sides 90 degrees to one another. I'd love to see how it looks and how far into the counter sunk holes it goes and how much the shape of the door edges are changed. I guess the slope on the Hammond boxes is about two degrees from what I've been reading.

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[Quigsworth]

Yea man, your not the only one it bugs. I got turrets syndrome, which shares some very OCD like qualitys.... And the crooked boxes drive me nuts!

I also did read that the angle was to help get the mold out.... I've actually been emailing and talking with Hammond and many other stomp box and project box companies trying to find answers and what I'm looking for. The reason you mentioned always came up.

Would you be able to post some pictures of a Hammond box you've sanded completely flat on all edges? Like all sides 90 degrees to one another. I'd love to see how it looks and how far into the counter sunk holes it goes and how much the shape of the door edges are changed. I guess the slope on the Hammond boxes is about two degrees from what I've been reading.

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Like I said, it's not dead bang square but it doesn't drive me too crazy...these are pics of my DNA30 Hammond (I think it's a 1550P, no card slots)...and keep in mind those are 1/4 cylinder magnets in the door so I had to over bore the doors screw holes...

 

[TUS172]

Yeah... I start out with a belt sander (80 grit belt) to take off the majority of the material. But its easy to get carried away with with it. Then go to finer grits by hand... Always paint though. Did you buff and polish that one? Could we get a pic of the "innards"?

 

[Quigsworth]

Yeah... I start out with a belt sander (80 grit belt) to take off the majority of the material. But its easy to get carried away with with it. Then go to finer grits by hand... Always paint though. Did you buff and polish that one? Could we get a pic of the "innards"?

Pretty utilitarian inside (don't mind the wood juice bottle spacer, I kept meaning to stick a 15ml in there...). To be honest I only built this as a sandbox mod, it was one of my first (and last) DNA chips, I wanted to try the FD 510's and I had an Origen looking for a home, it's really not a bad little mod but it just doesn't get the love like my mechs...as for polishing it, bringing a shine to cast aluminum (and keeping it) is a full time job...not gonna happen

 

[Gummy Bare]

Wow Quigsworth, thanks for taking the time to snap all those shots for us. Pretty cool looking box mod for sure. Those edges are pretty damn close to dead on.

What would happen if you did sand it dead flat on all sides? I'm thinking there should be enough metal, but it would go deep into the counter sunk lid holes.... Maybe even clean into the screw hole? I'm not really sure as I haven't sanded mine yet, I've been waiting on a buddy with a little home shop with some nice power tools. But I might just have to get some paper and a piece of wood and go to town.

I was thinking, if it went into the counter sunk holes I could fill it up with something (JB Weld maybe) and sand that flat as well. I'm just not sure how I would get the magnets or some other form of fastening the lid/cover closed.

I'm open for ideas on getting some Hammond boxes dead on flat 90 degree sides to one another. I know someone has had to have done it before.

Thanks again for the pics.

 

[Dougiestyle]

Your speedbump is with the coutersunk holes on the lid. Here's the solution: Custom lid! This opens the options to Lexan, plastic, sheetmetal or wood. You can get the edges of the box 90* true and have a custom door. No worries with the screw head holes, now!

 

[Quigsworth]

That's a good option Dougie...great way to change it up a bit...I've seen a lot of these boxes on the Italian forums (real popular with then for some reason?)...but one guy made a lid out of some rare hardwood...looked awesome, though if I where to be picky he went a little thick on it and threw the lood out of balance...I'm very particular in making sure the lid is screwed in place before making any measurements...the RDA/firing button has to be centered (with the lid on ).

I think you'll be fine with the C/S holes...even if you encroach a bit...everything goes away under the buffing wheel

 

[Gummy Bare]

Your speedbump is with the coutersunk holes on the lid. Here's the solution: Custom lid! This opens the options to Lexan, plastic, sheetmetal or wood. You can get the edges of the box 90* true and have a custom door. No worries with the screw head holes, now!

That is a pretty good idea. I'm not sure if I have the equipment to do it (or the smarts, lol). How would I go about doing it? Sanding the box edges flat, then trying to make a door out of lexan that would fit correctly and hope the edges would match up? Seems like maybe getting the lexan attached to the box and sanding the edges down together (box & lid sanding) would give me a true flat and uniform edge on the thing. But how would I get the lexan lip fastened to the box wile I was doing the sanding?

I love the idea, just not exactly how to go about it to insure the end result of completely flat edges.

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