2 of assembly instructions continued:
Now we will begin
construction of the aluminum cooling chamber.
9. To determine the size
of the aluminum cooling chamber needed for the Canon 450D, I first
made a mock-up using thin cardboard. Construction paper would
also work well if you are sizing the chamber for a different size
camera. I then used the cardboard mock-up as a template for cutting
the aluminum sheet. An aluminum sheet that is at least 11.75"
by 15" in size is needed. The 24" by 24" aluminum
sheet I bought is large enough to make two boxes. The box I built
that is just large enough for the Canon 450D has these dimensions:
This photo below
shows the aluminum sheet with dimensions and how it was hand cut
using a hack saw. The photo also shows the location of four slots
that are cut to allow bending the one-half inch wings used to
shape the box. File any sharp edges on the cut aluminum.
10. The aluminum sheet is
very thin (.025 inch) and easy to bend by hand. To assist with
bending the aluminum sheet I found two pieces of 2X4 wood to be
useful. One piece was 6.5 inches in length; the other 3.25 inches.
The first bend to be made will be of the four one-half inch wide
wings using blocks of wood. After bending with the blocks of wood,
hit the block of wood with a hammer to make a good 90 degree angle
as shown below:
11. The photo below shows
all four wings bent upward:
12. Bend large panels upward
at 90 degree angle using blocks of wood in corners for support
during bending. Use hammer as needed for a good 90 degree bend.
13. Bend the end sections
upward. I used the 3.25" piece of 2X4 wood to assist with
this bend as shown below:
14. Here is a photo of the
cooling chamber with the end sections bent upward:
15. The four wings will now
be fastened by drilling 1/8 inch holes, two holes in each wing
as shown and fastened with small 1/8"-3mm rivets and 1/8"
- 3mm rivet washers. (Small bolts and nuts could be used here
instead if you wanted.)
16. Use the metal peltier
support plate as a template for marking four holes in end of the
aluminum box. This area should be fine sanded on both sides for
best heat transfer for the peltier. I wet sanded this area using
600 grit sandpaper. If you have a finer grit sandpaper, use it.
You want this area to be as smooth as possible for good heat transfer
and the sanded area should be mirror-like in appearance. Drill
out the holes marked with a 3/16" drill bit. Clean peltier
area on the aluminum chamber where sanded with denatured alcohol
on both sides
17. Spread a thin layer of
thermal paste on the peltier and also on the inside of the metal
peltier support plate. A very thin layer of paste is best for
thermal conductivity; you should be able to see through the paste.
Attach peltier/heatsink with the original four screws and rubber
18. With the peltier now
attached to the cooling chamber, install pop-rivets and rivet
washers. I also used J-B
to seal the seams of the aluminum cooling chamber just before
pop-riveting. I dressed all seams of the aluminum cooling chamber
with J-B Weld Epoxy:
19. Test fit the camera inside
the cooling chamber. Notice that the camera's flash nosepiece
on the top of the camera body protrudes slightly forward, more
than the camera T-ring does. We will cut a small hole (slot) in
the cooling chamber to allow the camera T-ring to be flush against
the cooling chamber wall:
20. With the camera inside
the cooling chamber, trace around the nosepiece and drill out
this area using a 5/16" drill bit. I used a small round file
to shape the hole and test fitted the camera. We will later apply
aluminum tape here, see Step 34.
21. Make a template using
a thin piece of cardboard by tracing the front of the camera with
T-ring and use it to mark off the center of the hole to be drilled
for the camera's optical path.
22. Use a 1 3/4" hole
saw to drill a hole in the front of the cooling chamber for the
camera's optical path. File all cut edges of the aluminum chamber
23. Make a template of the
bottom of the camera body by drawing around it on a piece of paper
placed on the bottom of the cooling chamber. Use this template
to mark and drill a 1/4" hole and enlarge if needed.
done! Finish the assembly using the steps on the Next