[nathanm]

Here's another option John.

[ErikM]

OK, a jigsaw or table saw! bob-with-many-digits, I've always thought jigsaw's don't cut straight, even on a straight-edge cuz the blade flexes. No? Maybe I just need to get a good quality one  

Check out the Bosch Jigsaw.  This tool is worth spending a few extra bucks on.  Blades last a long time and when fresh make a smoooooth cut.

bubba, I'm thinking of not getting a tablesaw. I've been ogling this saw from Festool, it comes with a straight guide that it latches onto. Kinda like how I used to cut panels but way better. What do you think of <a href="http://212.172.181.83/festool.us/cat_mediando/index.cfm?module=display_single_produ ...

Run away John.  This may be a bit easier to set up than the saw board, but probably not by much and not much more accurate.  PITA.  For the same money, I'd look for a Jet 10 inch contractor's saw.  You'll use it more.

I actually found the best solution for woodworking tools, a wood-worker's club.  Woodcraft stores have full shops that you can access with paid for membership.  I joined one last week and have already learned more about woodworking then by futzing around for a year.  I can't tell you how cool it is to have access to two HUGE delta table saws with quality fences, not to mention to joiners, planers, lathes, presses, sanders, and VACUUM'S!

[MaxCast]

John, what is the size of the case you are trying to build?

[JohnR]

MaxCast, the first one would be for my 100W AKSA... overall size of the amp would be 17W, 14D, 3.5H, something like that. The top, bottom and side panels would have to account for the heatsinks as they would tap into them. So, not large peices of metal. I could get 'em cut as suggested by beat and ETR but the question for now is can I get equipped to cut it all myself...

Nathan, very nice, but I'm concerned about the cost of shipping to Aus!

ErikM, hm... you mean just a regular 10" circular saw? Man, my back was breaking setting up the straight edge back in Bezerkely, and I could never get it close enough to make boxes bigger than a foot cubed or so. The club idea is a good one... hm maybe I could do a course at a community college or something and get access to some stuff  

[beat]

There ya go,
I like that last idea, take a welding/metals class. I have a 100 craftsman 10 inch saw with a 7.5 inch nonferrous metal blade on it, It worked perfect when I cut my 3/8ths aluminum..I think it was even hardened.

[bob82274]

Ok I re-read this and actually thought about how thick 3/8" Al is.  Yea don't use a jigsaw for that.  You can cut straight as long as you are using a thinner piece of metal, a good jigsaw, and the correct blades.

[ErikM]

ErikM, hm... you mean just a regular 10" circular saw? Man,  ...

No, a 10 inch portable table saw.  I too gave up on the saw-board idea.  The Festool saw just looks like more of the same.

I looked for continuing education classes in my area, but they are all "Martha Stewart" style cooking and doily making classes, nothing macho like shop.  
Glad I found the woodworkers club.

[TG]

Wow John - you're brave, I wouldn't even try to work 3/8" plate  
Look in the Yellow Pages for metal fabricators and give them a template - you'll probably find they offer other services like powder coating that you might also want.  I love DIY but some things are just too serious for this chicken  

Cheers

[Rocket]

hello john,

just like to add my 2 cents worth.  if your after a metal finish chassis and want an excellent job you can't go past a laser cutting company.  it will provide you with an excellent finish and then have it powder coated like i did.  it all cost under $200 au and i'm fussy and i was even happy with the way the amp looks.

regards

rod

btw the nirvana should be finished this weekend can't wait to hear the improvement.

[JoshK]

TG - Have to give you props on the music selection!

[JohnR]

Hm, OK I'm coming back down to earth now...

Thanks for your comments, very good food for thought...