On Thu, 03 Feb 2005 18:11:42 -0600, DougC wrote:

Aluminum can be "hand-machined", if you have a Dremel and buy some
smaller steel bits--the ones they sell for "wood and plastic use only"?
I found recently that those work pretty well on 6061-T6 aluminum, but
you must work very slowly cutting just a bit at a time and keep a firm
grip on the Dremel or it will chatter and chew up your workpiece. You
could use quarter-inch-thick Aluminum sheet and slowly, carefully mill
out even the big tube base holes, I'd bet. ....

My father used to machine 1/4 inch aluminum with a router. He'd
make a wooden template for the router, and take his time, but
get beautiful results. I've always been too afraid to try it,
myself.

Sescom will do punched lightweight aluminum chassis to order,
and can anodize them afterwards. They're beautiful, but you'll
need to build an internal framework of various angle stock to
bear the weight of transformers and such, and to carry the load
to the sides past the flimsy (for tube amps) corners. Maybe worth
the trouble and cost for some projects.

Once you've seen a punched panel anodized through the holes
you may fall in love with flimsy chassis. Or maybe not.

Good fortune,

Chris Hornbeck