G506/G508 Firewall pad project

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G506/G508 Firewall pad project

Postby pfarber » Tue Feb 18, 2014 6:40 pm

I found this thread:

http://g503.com/forums/viewtopic.php?f= ... 2&start=90

What I really want to mention is that while the project looks formidable... its actually a very simple process. Well, the hard part is getting an original. Short of a complete original you need to create a pattern. What I find really interesting is that the OP never actually tells you how it will be made. Its a super simple process using a STEEL RULE DIE.

This is what a steel rule die looks like:
srd.PNG
srd.PNG (355.13 KiB) Viewed 2570 times


Its all done via CNC now. A CNC router will cut a pattern in a piece of wood. The channels are then used as a guide for the steel rule... which is literally a sharpened piece of steel about 1/2in tall and sharpened on one side like a knife blade.

Most steel rule dies are priced per inch. Typically $1-4 dollars/inch + setup. This firewall pad benefits from only needing one die to cut both the facing and the insulation... you can stamp the face, modify the die slightly, and stamp the insulation.

You can also order steel rule by the foot and and prebent angles so you are only paying for the steel, and you make the die board yourself. Punch outs (bolt holes, panels etc) are also 'standard sizes' to also lessen the cost. Lots of people use a router or a thin bladed saw for DIY cutting of low volume parts.
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Re: G506/G508 Firewall pad project

Postby pfarber » Fri Feb 21, 2014 6:18 pm

Since I had some free time at work I figured I'd look for some cost info on a steel rule die for the padding. A G508 firewall pad would be simply as it just cardboard and not insulation/facing.

I found a place that would generate a quote and this is what I got:

A custom estimate has been prepared to produce the following die:
Material Being Cut: Cardboard
Approx. Material Thickness: .125
Steel Rule Height: Not Sure
Width of Part: 48.000 inches
Height of Part: 30.000 inches
Number of Holes (Punches): 15
Number of Cutouts: 6
Shape of the Part: Custom Shape
Type of Corners: N/A
How Many Cavities Up: 1
Spacing Between Cavities: Not Sure
Tolerance Expectations: +/-.010 (Standard)
Die Board Thickness: 5/8" inch board (Standard)
Shipping Address ZIP Code: 17936
Estimated Die Price: $553.12

I guessed a lot of the numbers because I didn't have my CCKW at work (hahaha)

Note this is not material costs... just the cost for a die. I'm sure if you shopped a dxf file around you could get sub $400.
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RIP Kimber 5/26/2022
RIP Yeager 1/3/2019
RIP TJ 3/25/2014
RIP Sugar Bear 8/29/2014
RIP Shilo 4/10/2015
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