Project Dashbox update...

OK, I have the Meccano 'girder' prepared for painting. However, I have encountered an unforeseen problem.

Enlargening a pair of holes in the girder (the first one I messed up: I opened out on of the holes nearest the sidewall, but the nut for the mount wouldn't fit there!

So, plan B: Open up another hole, this time in the centre line. Job done on second attempt ;)

However, on testing the fit with my phone fitted into the mount, it was very clear that a LOT of mass was involved, so much so, that I'm concerned that the rivnuts (to be installed) won't be able to handle the weight of the mounting with the phone attached, without bracing from the top - in other words, it'll pull out the rivnuts out of the dash top, unless the box is also mounted on top of the girder, providing reinforcing strength.

Oh, FUDGE, And other words.

So, I'm going to paint the girder (no reason not to), and consider my next move.

Irritating is not the word... :(

Anyhow, the photos. There are three here, showing the girder in detail in two (top and bottom shots), and the tools involved; I utterly shagged two dremmel-style wire brushes, and two sanding bands, in preparing the surface of the girder to be painted (I used my Clarke rotary tool for that).

Ye gods, that Zinc is tough stuff!

The holes in the girder were enlargened with a 6.5mm high speed steel drill bit (using my Bosch PSR-18 cordless drill), and I then de-burred the holes using a couple of grinding stones in my Clarke rotary tool.

In between every part of the job, I had to recharge the Clarke tool; that battery needs replacing, but they don't sell spare ones :( Guess that's another task for me to do... crack open the battery casing, and replace the NiCads in there with new ones... shouldn't bee too hard ;-)

Oh, and note the filter mask. ANY time you're sanding something, be it wood, plastic, or metal, you produce dust. Metallic dust is especially bad news for your lungs. So, if you're sanding - especially using power tools to sand something - wear PPE; in this case, a filter mask and goggles. You don't want that crap down your lungs, or in your eyes. Oh, and wear gloves, too, if you use power tools - even a Dremmel or similar rotary tool.

More tomorrow...