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Thread: Passive re-casing project

  1. #1
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

    Default Passive re-casing project

    I'll kick off the first DIY post.

    So I bought my fantastic passive pre-amp from a very good friend who happens to be a bit of an electronics genius. Handy for a bod like me! Anyway, once I'd begged him relentlessly for weeks to sell me the damn thing (and I'd actually got round to paying him), I decided that I would change the somewhat utilitarian case for something with a little flair to it.

    Here's what I started with:




  2. #2
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

    Default

    At the outset of the project I'd spent a great deal of time arguing with myself over materials. I considered granite, marble, aluminum and even acrylic. However, once my limits of technological know-how finally gripped me I decided on two types of wood.

    Why wood I hear you ask? Well, two reasons:

    1. The Beechwood matches my speakers
    2. It's really easy to work with and I'm a dab hand with woodwork tools.

    So I decided to go for a two tone look, the main body being in a mid-tone wood (Cherry) and the base and top being in a light wood (Beechwood). Luckily I stumbled across a chap on ebay who made Cherry boxes in his spare time and sold them for absurdly low prices.

    I managed to get this for a fiver!:


  3. #3
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

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    So the first job was to dismantle the existing casework. Mmm, easier said than done as some of it had been riveted and had to be drilled out. Still, it came apart nicely and primarily with no damage.




  4. #4
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

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    Then I encountered my first problem.

    I'd forgotten to check how thick the wood used to build the cherry box was. As no luck would have it, it turned out to be too thick for the shaft of the volume switch to pass right through. Luckily I'm a dab hand with a drill and have a selection of clever bits. Having ONE chance to get it right, I went for broke. Luckily it paid off!



    Then I drilled some holes for the phono sockets on the rear panel.


  5. #5
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

    Default

    Next job was to decide on the layout. It made sense to keep the transformers as far apart as possible to avoid any interaction. At this point I earthed the two transformer cases together but I didn't go for complete shielding.


  6. #6
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

    Default

    Next was to bolt in the volume switch shaft. Nice and tight to avoid any slippage.



    It was then I realised that the same issue of the thickness of the wood was going to affect the phono sockets. However as luck would have it I had a spare project box knocking around so I decided to install the sockets on the box and then fit it to the rear of the case as thus:


  7. #7
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

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    Next was the lining up of the base. In my experience I've found relentless measuring to be counter productive, so I lined the case and base up by eye and went at it with my power screwdriver. AAAARRRR!



    Lined up and screwed in position:


  8. #8
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

    Default

    Then for the feet.

    Having had loads of component laying about the place, I borrowed a set of feet with a champagne ring on them from an old Aiwa tapedeck. As it happens I've since changed them to spikes, but in fact I have changed them back as they really help the sound.

    Just three feet as four is a leveling nightmare!



    Back on its feet and sorting out the top.


  9. #9
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

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    Then I had to figure out how I could get the top on nice and firmly but with still having access to the innards in case of problems. I paced furiously looking for answers and then finally came up with a set of 'DIY' positioners and a couple of spring clips.

    Here it is with the lid on:



    Last thing was to fit the gorgeous Audio Note gold plated brass knob - mmmm, feel the luxury.


  10. #10
    Join Date: Jan 2008

    Location: Norfolk, UK

    Posts: 6,209
    I'm BigBobJoylove.

    Default

    And the finished article in my rack:

    Luckily just the right height! I forgot to measure the rack beforehand.




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