Brief Description: Map box final trim and construction,
I focused my energy today on finishing the modified map box so that it could be installed in place on the panel face and within the panel and deck structure. First task was to trim the provided 2 part box lengthwise for a final time for proper fit between the panel and sub-panel. I did this by taking the box apart and measuring, marking and then cutting by hand, the cut edges were then trimmed on the bench grinder and then a hand file was used across the cut to get a straight and true edge on both parts, first the bottom then the top (as I had marked them).
I then had to design a method of closing up the open end I had just trimmed off (the standard 'flap-over-flap' method was too bulged and did not fit into our modified space given the modified installation of the box). The trimmed bottom and top of the box were riveted together as per the drawings making a solid box structure. What I came up with was to simply make up a 'frame' at this open end of 4 lengths of angle material. The two shorter lengths had to be shaped and trimmed to fit both the frame bottom and top as well as the coverlapping and riveted box parts...this was harder than I thought it would be and took some time and a failed attempt or two before I finally had as good a fit as I was going to get. Having clecoed the frame in place in the box I match-drilled to #30 and then rivetedthe parts in place to make 4 flanges on which to install my 'box end' which I made from scrap .063 material.
