[Gordon Steadman]

These chassis are certainly neat although I don't like the idea if sticking the motor in. However, it would be easy enough to make up a bracket for each end of the motor and bolt them on.

I'm suck firmly in 60's territory using brass

What do you do with the industrial scale offcuts?

[dazee]

What do you do with the industrial scale offcuts?

You could reduce this by making 2 chassis at a time from the opposite sides and careful cutting.

[KensRedZed]

Hi Dazee. Thank you for your kind words. I'm very happy that you're going to get started in scratch building. 

Please ask questions here or send me a PM if you get stuck?

Hi Gordon. I take the cut offs to the metal recycling company for coffee money.

5-minute Epoxy is the fastest way to install, and remove a motor. Everyone in my club laughed at first. 2-years later, many members are following my lead. It's a proven method, and works fantastic.

Cheers,
Ken

[KensRedZed]

I forgot to say that it's not really possible to safely make a chassis with the cut offs. You'll take your finger off before saving a dollar.

A 36" inch length of 3/4" square aluminum tubing is $18 Canadian. The average chassis is about 4.25" inches. That means I get 8 chassis for $18 Canadian. That's $2.25 per car. How much are we trying to save by risking fingers for some fancy bandsaw cuts? I can easily afford $2.25 per car. 

[KensRedZed]

I'm saving the cut offs to make motor brackets for you, Gordon. That way you don't have to use glue. 

[BAracer]

Ken

I'm not doubting your logic in any way, but being the mathematical genius you are, and with a bit of tessellation as dazee hinted at, you could possibly double your production runs, especially once your machine thing arrives...

   

[KensRedZed]

Hi Jeremy,

These cuts still need to be made on a bandsaw even after the mill arrives. The mill helps to make all the holes a bit more precise. A mill will specifically help with the guide hole, and crown relief areas.

Thank you very kindly for your drawing. Your lines look perfect in theory. But a bandsaw is a very dangerous machine. I will do anything to make the cuts a bit safer and easier to do. My first 10 chassis's were all over the map until I came up with a repeatable cutting system that was the least dangerous to perform. I like my fingers.

[Gordon Steadman]

I'd do that on the bandsaw if it was wood but not sure about the metal. You'd need a fairly slim blade at least.

[KensRedZed]

The material only cost $2.25 Canadian per car. That's $1.50 US, or maybe one Euro? How much trouble are you willing to go through to save half a Euro?

Yes, it certainly can be done. Is it worth it? Not to me. I need a better reason than just a few pennies. I'm good with just the bottom half of the aluminum square tubing. The less time spent on the bandsaw with challenging cuts, the better. One car at a time seems to be the best outcome so far.

   

[JasonB]

Bandsawas are deceptively dangerous finger eaters. I'm not sure I'd bother with an awkward offcut.