rbalagopalan
Well-Known Member
It has been my endeavor that being a Mechanical engineer that too having direct contact with all sorts of industries that I should make my self any Stand or Rack that I need. That too knowing the nuances of fabrication / machining processes it will be criminal on my part to buy from the show rooms and pay hefty price for no reason (may be lack of time to concentrate - a lame excuse).
So in that process I had built an AV Rack and a Book Shelf stand of 4 pillar design for my own use. I had just put a few white paper on my initial drawings just to show that how did I chalk out the design. Though the out come was not accurate as per the white paper mm to mm the overall finished product is the same, as I had to do couple of modifications to improvise during the manufacturing process in consultation with the fabricator.
The finished and Assembled AV Rack is weighing approximately 75 kgs. The Bottom most shelf has got 3 beams and weighing 17 kgs to support heavy power amps and other shelves with 2 beams and weighing 15 kgs each. I didn't want the fastening bolts to carry the weight of the Shelves and the components hence I had designed the legs with Milled slots so that the shelves will directly rest on the legs and hence the load bearing is straight on the legs and not on the fastening bolts.
I felt positioning the 4 legs either in 4 corners on sides or front & back is very conventional and does not add any designer value. So I had decided to keep left and right legs at a distance of 1/3 from the front and the rear 2 legs at a distance of 1/4 distance from the left and right corners. This has really made the Rack to look with elegance and neat architecture. With regard to the fastening bolts I thought a normal hexagon bolt or allen cap screws will make the Rack to look industrious and not a luxurious indoor equipment hence I decided I will go with Mushroom head allen cap screw and to add contrast I went in for SS304 material.
The overall size of the each shelf is 42" wide x 21" deep which is double width one.
With regard to the Book shelf stand the Four pillar stand was the choice of our forum member Mr. Mohamed Naseer. Though primarily I thought I will make one for me It was ultimately developed for Naseer. This particular design is non dismantlable fully welded structure. The weight of the each stand is around 19 kgs with out any fill in the 4 pillars.
There is a provision at the bottom individually in each pillar for filling fine sand, Iron balls or lead shots whatever. Having made the stand robust I didn't want to go in for ready made spikes which will not do any justice to the stands I had designed the spikes my self for it to do justice to the size of the stand with regard to looks and performance.
https://plus.google.com/photos/110165001878262859830/albums/6006067470246566241
While claiming the design and development I do admit that there are some issues with regard to finish, like the seam in the 4 legs of the rack could have been put inside ie the milling should have been done on the seam side rectangle tube, of course it is not visible to the naked eye though.
The welding finish is not up to the mark cause the experienced TIG welder was on long leave and had to do with the ark welding (as explained by the fabricator) These flaws can be eliminated 100% in future as we had come out with lot of other way to do it. Even No welding will be visible from out side or dismantlable stands can be done.
Coming to the critical question of cost of finished product it is fractional when compared to imported ones and far less than the Indian manufacturers / brands. In fact I didn't want to post it here with an apprehension that this is not some thing great to be boasted, but the opinion and encouragement of our many forum members like Madbulram, GeorgeO, Srini, Naseer, Rajiv, Clearcut, etc.,(if I had left any names please excuse me) during their visit and many non member hifi enthusiast has made me to post it here.
I have no problem in openly declaring the cost here if this forum allows. Please clarify me I will post it here.
I don't know what to elaborate further as it will run in to pages I will stop here and look forward to the members opinions /comments and questions.
NOTE: I can get this done to any forum member to any size and shape based on their design, photo or narration on absolutely non profit motive. This is strictly for their personal use and not for any profit making sale. Only request is please allow 3 to 4 weeks of time.
Thanks
R. Balagopalan
So in that process I had built an AV Rack and a Book Shelf stand of 4 pillar design for my own use. I had just put a few white paper on my initial drawings just to show that how did I chalk out the design. Though the out come was not accurate as per the white paper mm to mm the overall finished product is the same, as I had to do couple of modifications to improvise during the manufacturing process in consultation with the fabricator.
The finished and Assembled AV Rack is weighing approximately 75 kgs. The Bottom most shelf has got 3 beams and weighing 17 kgs to support heavy power amps and other shelves with 2 beams and weighing 15 kgs each. I didn't want the fastening bolts to carry the weight of the Shelves and the components hence I had designed the legs with Milled slots so that the shelves will directly rest on the legs and hence the load bearing is straight on the legs and not on the fastening bolts.
I felt positioning the 4 legs either in 4 corners on sides or front & back is very conventional and does not add any designer value. So I had decided to keep left and right legs at a distance of 1/3 from the front and the rear 2 legs at a distance of 1/4 distance from the left and right corners. This has really made the Rack to look with elegance and neat architecture. With regard to the fastening bolts I thought a normal hexagon bolt or allen cap screws will make the Rack to look industrious and not a luxurious indoor equipment hence I decided I will go with Mushroom head allen cap screw and to add contrast I went in for SS304 material.
The overall size of the each shelf is 42" wide x 21" deep which is double width one.
With regard to the Book shelf stand the Four pillar stand was the choice of our forum member Mr. Mohamed Naseer. Though primarily I thought I will make one for me It was ultimately developed for Naseer. This particular design is non dismantlable fully welded structure. The weight of the each stand is around 19 kgs with out any fill in the 4 pillars.
There is a provision at the bottom individually in each pillar for filling fine sand, Iron balls or lead shots whatever. Having made the stand robust I didn't want to go in for ready made spikes which will not do any justice to the stands I had designed the spikes my self for it to do justice to the size of the stand with regard to looks and performance.
https://plus.google.com/photos/110165001878262859830/albums/6006067470246566241
While claiming the design and development I do admit that there are some issues with regard to finish, like the seam in the 4 legs of the rack could have been put inside ie the milling should have been done on the seam side rectangle tube, of course it is not visible to the naked eye though.
The welding finish is not up to the mark cause the experienced TIG welder was on long leave and had to do with the ark welding (as explained by the fabricator) These flaws can be eliminated 100% in future as we had come out with lot of other way to do it. Even No welding will be visible from out side or dismantlable stands can be done.
Coming to the critical question of cost of finished product it is fractional when compared to imported ones and far less than the Indian manufacturers / brands. In fact I didn't want to post it here with an apprehension that this is not some thing great to be boasted, but the opinion and encouragement of our many forum members like Madbulram, GeorgeO, Srini, Naseer, Rajiv, Clearcut, etc.,(if I had left any names please excuse me) during their visit and many non member hifi enthusiast has made me to post it here.
I have no problem in openly declaring the cost here if this forum allows. Please clarify me I will post it here.
I don't know what to elaborate further as it will run in to pages I will stop here and look forward to the members opinions /comments and questions.
NOTE: I can get this done to any forum member to any size and shape based on their design, photo or narration on absolutely non profit motive. This is strictly for their personal use and not for any profit making sale. Only request is please allow 3 to 4 weeks of time.
Thanks
R. Balagopalan
