DIY Battery power supply (PSU) for hiFace Evo – part 2

In part 1 I’ve bought hiFace Evo, and done thorough research; purchased all needed parts; also test schematic. This time I’ll do metal work and painting.

1.
I have bought a cheap Thin Wall Diecast Aluminium Project Box 145x95x49mm from eBay. They also have painted versions. This was the smallest enclosure to be able accommodate battery.
DIY Battery power supply (PSU) for hiFace Evo

2.
One has to use masking tape or stick a paper with print templates on it, in order to do a metalwork. Surface stays protected against scratching and you can draw your marks / design on. Design doesn’t need to be just drawn by pen, but can be designed on computer and then printed.
You cans see, where about is battery and position of mini-XLR connectors, LEDs and switches.
DIY Battery power supply (PSU) for hiFace Evo

3.
The opposite side of power supply. Just a battery and charging mini-XLR connector.
DIY Battery power supply (PSU) for hiFace Evo

4.
My home drilling rig 🙂 If you want to do at least a little bit accurate drilling, then drill holder and vise is a very essential piece of equipment. Use silicon baking pad to keep equipment steady on the table. Pad can withstand pretty high temperatures. Very useful for soldering indeed. (cost only few quid)
DIY Battery power supply (PSU) for hiFace Evo

5.
Use center punch first to make sure, that drill will hold in place instead of traveling around surface. Then drill using small and increase sizes to bigger and …
DIY Battery power supply (PSU) for hiFace Evo
 
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6.
… to final size. It’s better to make them at least 1mm bigger than actual size, because of the paint.
DIY Battery power supply (PSU) for hiFace Evo

7.
Die cast enclosure was having some imprecisions, so it’s better to screw down the lid and file them out. I have finished it with no.180 sand paper and metal wool.
DIY Battery power supply (PSU) for hiFace Evo

8.
And now paint. Cleaned with white spirit and my favorite lighter fluid.
DIY Battery power supply (PSU) for hiFace Evo

9.
This is silver version for friend of mine. Very shiny with truly spectacular look! Also pretty expensive: one coat of primer, few coats of silver metallic spray and three coats of Clear Lacquer spray paint. Now bad news: I messed it once, so it all had to be scraped down and re-sprayed again. Arrrgh…
DIY Battery power supply (PSU) for hiFace Evo

10.
And this is version for me. Bottom lid.
DIY Battery power supply (PSU) for hiFace Evo

11.
Only one layer of Hammerite 5092965 Metal Paint used. More retro / industrial look, which I like very much.
DIY Battery power supply (PSU) for hiFace Evo

12.
Top and bottom of enclosure. Soft black silicone self-adhesive feet 6.0 x 3.0 mm attached to bottom lid. It is much darker in real.
DIY Battery power supply (PSU) for hiFace Evo

13.
To even the price of silver paint I wanted to give it a bit more personal touch by engraved badge. Pretty expensive self adhesive £10 gold thing. I guess you have pay extra for custom made stuff this days.
DIY Battery power supply (PSU) for hiFace Evo

Don’t forget to check out part 1 and 3 if you want to know more.
 
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