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The Face Plate

A project log for Designing a Modern Tubeamp (Matthews 14)

Ground up design of a guitar tube amp using old and new technology.

collin-matthewsCollin Matthews 01/15/2024 at 01:510 Comments

Making the face plate took a long time of planning... I knew I wanted brushed aluminum from prior experience but I did not have a good way to cut and machine it. Over the course of building a few amplifiers, I procured both a router and table saw. This gave me the ability to machine everything needed.

The process was roughly as follows below:

  1. Cut a sheet of aluminum I purchased from Speedy Metals online. I oped for 1/8" here. I did this on a 10" portable table saw using a blade designed for metal.
  2. Used masking tape on the front and measure out a hole pattern for dials and switches. Then use a center punch and drill out the holes to the size needed.
  3. Using a router with a carbide 1/8" endmill, router out the slots for the 5 band EQ. This was by far the most difficult part. I found the key is to go slow, and take it in multiple height passes. Some WD40 as lubrication also made a huge difference in preventing the chips from sticking to the bit during machining. I marked the top and bottom of the slots with sharpie, and used a block of wood clamped to the router table as a guide for the edge of the aluminum.
    I used a 1/2" square dowel to space the aluminum plate and move the wooden guide over to keep a consistent 1/2" spacing of the slots.
  4. Using a similar approach, on the back side, route out half depth for potentiometer and switch keys that prevent them from rotating...
  5. To give a brushed aluminum look, start with 80 grit sandpaper till major blemishes are removed, then work down to 120 or 150 grit. Only sand in 1 direction, I find the long direction works best. I also found putting 2 screws into a board aligned with two of the holes on the plate gives a good method to hold the face plate in place as you sand it. Also - I always wet sand, I would recommend it.
  6. Coat the face with a few layers of polyurethane to smooth it out and protect the aluminum brush finish. This also makes it easier to write on with paint pen.
  7. I used oil based paint pen, because I wanted to put 1 layer of polyurethane over it for protection, it did not smear. I think water based would be ok as well. Just give either option a few days to dry well first.

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