See through gear chain guard
I'm making a thickness sander and I realized that there was a good chance that I would be able to do something stupid and get my hands / pants caught in a moving chain.

I decided to make a box for it out of clear plexiglas so that I would be able to see it running. I could have made it out of wood, but that would not have been as cool as this...

Step 1: Make the vectors for the box and make a cardboard test

See through gear chain guard
See through gear chain guard
See through gear chain guard
See through gear chain guard
See through gear chain guard
See through gear chain guard
See through gear chain guard
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There are many laser box makers on the web, but the one that I like the best is http://boxmaker.rahulbotics.com/

All you have to do is to plug in the height, width, and length, and you have a PDF that you can pull into corel draw and you are well on your way to making a box.

I needed to make some changes to the files, so I regrouped the vectors for each of the sides. One of the things that I had to figure out was how I was going to affix the box to the thickness sander. I also had to figure out how I was going to get the box over the chain.

I always make a test box out of cardboard first. This helped my to visualize the problems.

Step 2: Laser Cut the Plexiglas

See through gear chain guard
See through gear chain guard
See through gear chain guard
Once I was sure that I had the design worked out with the cardboard mock-up, I then laser cut the plexiglas.

I leave the paper on so that the soot does not get all over the plexiglas. If you want to see how to laser cut, check out this instructable:


Step 3: Glue it together and screw it on

See through gear chain guard
See through gear chain guard
See through gear chain guard
I used weldon to glue it together. This instructable shows how to glue plexiglas.

After it was dry, I used a couple of wood screws to affix the case. Notice that the entire case is glued together. I made sure that I had hole pre-cut in the plexiglas to ensure that I would be able to attach the guard.

I am one step closer to getting this thing running. I get the feeling that this will never end.

I made it at Tech Shop
 
 

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