Joining two cases, what method?

[Mord]

I have to cases ready for project behemoth where by i plan to fix these cases together. My only (major) problem is I don’t know or have the tool for welding.

The only tools I do have are: a dremel, jigsaw, hand drill, soldering iron and basic electronics tools such as screwdriver / pliers etc.

Bearing in mind I want to join these cases side by side permanently, what sort of options do you think I have?

[KnowlesTech]

How about JBWeld it works miracles with two metal objects you want to join permanently.

[Mord]

Whats JB weld?

[Fire58Mech]

It's a type of glue. Go to a hardware store and they should have it. Mix the 2 bottles together in equal amounts and alppy.Be careful becouse what ever touchs it once it's bin joined it will never come off agian. Use gloves and newspapers.

[shard]

on the sides cut a hole that covers most of left side of right case and the right side of the left case, then drill holes for bolts and and bolt the cases together!

[Bashar]

How about duct tape? It can fix or hold anything :)

[RevelatorHarmon]

well, if you are looking to hold them together, I suggest riviting them, cut the sides out, but leave yourself a ridge, and put rivites around it, they are very strong and the final product will look nice.

[Mark620]

Welding thin metal such as a case is not advisable, you will surely melt some holes in it, unless you are a very experienced welder. Glue(JB Weld) is just messy and is only as permanent as the substrate is(paint) unless you sand the area(s) down to bare metal.

I would use rivets or sheet metal screws or bolts and nuts.

[rogerdugans]

Lots of options, and welding is actually the least good- TIG would be best (expensive equipment) with a small MIG being the next best choice. (Less than TIG, but still not cheap.)
BTW- I am a welder. ;)

As for the other options:

For a permanent join, rivets or bolts are fine, and both better than epoxy for pure strength. They will still leave you with a seam between the cases (mega-case halves) though; I would say use a metal epoxy like JB Weld to fill the seam for a smooth look that won't crack as easily as a plastic body filler.
Metal body fillers are available too, and they would probably be easier to work with than JB Weld but they are pretty expensive I think.....could be wrong there though. (I'm a welder, not an auto-body expert. ;))

I like JB Weld- it's not THAT hard to work with and it does hold pretty well without cracking, etc.; feather the edges and sand everything down well and I think the combination of bolts or rivets and metal epoxy would be perfect.

[Suran]

Me personally, I would do it with bolts. Substrate welds are fine and dandy, but I prefer knowing that metal is whats keeping my metal case together, not a substrate glue. Although you COULD use epoxy or substrate glue to fill in the gap....

Say, what are you planning? More info! Sounds neat!

[[OC]Lucifer]

Use bolts to join them, then use body filler to fill the crack all the way around, sand it smooth, and then paint it. No one will be able to tell that it wasnt always one case.

[Mord]

I think ill use bolts, but with metal plates on either sides to increase the surface area that the bolts are sqeezing on, should stop the case from bending or the bolts from ripping out the metal. Then use filler or something on the gaps.

Cheers for the advice.

[nissmo300]

I have to cases ready for project behemoth

Why not get yourself one of those huge cube cases instead?

[Mord]

Originally posted by nissmo300


Why not get yourself one of those huge cube cases instead?

Cos im a cheap b@sterd and like modding?

[rogerdugans]

rofl!

Mord, you are a kindred spirit! :D

Why buy something expensive when you can make it yourself and have the joy of DOING as well as the joy of having, eh?

Good luck with the case, amigo!

[[OC]Lucifer]

This is Alternative Modding, not Alternative Buying. :p

[syberspy9]

yes mod on with jb weld i used it and its hard core

[RangerJoe]

i would weld it, then sand the whole thing down. mig would be easier to fill the gap between the two, but a tig would look a lot better. im learning to weld right now. i would try to do something on my case, but with aluminum you have to use an AC current, which is about 1000x more difficult than steel/stainless welding.

anyway. my vote goes for welding it.

[Mord]

Well, i had a go at the cases with a drill, but they seem to be made of JNC case quality steel and they warp quite easily.

I dont think id trust them to hold bolts understrain, which is a shame because they are built quite nicly, even if it is with crap metal.

I suppose ill have to reinforce the metal some how, or "sandwich" both cases top and bottom with sheet aluminium.

[dreadlord79]

Try using "L" iron or a metal plate with quite a few holes drilled through it and then put rivets through the plates and the case metal which might not look the best but would definitaly strengthen your joints and would be easier if you wished to make them to open from the center so you can work on them in the future unless you have made another way to work on it.