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Post by rodney on Jan 17, 2020 9:11:19 GMT
My last few threads have been around a case theme. Maybe I should try to consolidate it into a 'case hacks' thread? 
anywayzzz...
I have two 2x20 unit wide cases and the case joiner kit from the Tangible Waves shop.
Because I don't have a dedicated place for my studio, I tend to pick it up and move it a lot. It would be nice for me to be able to fold it over and stash it away somewhere or just have it more compact when carrying it around.
As noted elsewhere, I like to go busking with my electronics so hanging everything from a guitar strap is part of my requirements in any design thoughts.
Using the standard acrylic and rubber case joiners and the supplied finger bolts, the clearance is a bit tight when folded over with the kind of random DIY stuff I have.
So, I decided to make some plywood ones with a bit more clearance and to eventually incorporate a handle for carrying it around. I'll talk about the handle in a later post.
After some measuring, I sketched out the basic design on some plywood then cut the pices out with a jigsaw.
Then, I drilled out the holes and put M5 bolts through so I could shape both identical parts together. That way, whatever shape I make with one will be echoed on the other and look more, uh, like I meant it to look that way.
The protuberance to the left is designed to jam up against a screw in one of the 3mm embedded nuts in the case. This stops the joiner from swivelling in the 'wrong' direction when not flat on a table.
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Post by rodney on Jan 17, 2020 9:28:29 GMT
I had to constrain the pointy bit so it doesn't stick out when folded over. The screw also keeps it from swiveling further in the other direction. The extra clearance is just enough for me to fit random non-AE standard items in the case. This month, I'm performing with a Novadrone and an old Korg Kaos Pad mini for effects. _  So far, so good
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Post by robertlanger on Jan 17, 2020 10:00:43 GMT
Great to see! Carsten had the idea to mount a rod in the middle of the hinge part between both hinges and get a carrying handle by this. Looks like your thing goes in this direction too! I'm open to make this as a variant if it's ok for you rodney? |
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Post by rodney on Jan 17, 2020 10:03:49 GMT
The next step will be a handle that doubles as a support to angle the case when on a flat surface - vaguely inspired by these things...
Because the M5 threaded inserts in the case are not intended to be lugged around a lot, and certainly not for guitar strap usage, the nuts can come loose. So far, I've super-glued them back in but it worries me that this might happen in a gig and I'll drop my beloved AE on the street somewhere.
For this reason, I'm also thinking about how to ruggedize some parts of the case without adding too much weight.
For the M5 nuts, I may just add another nut and washer inside the case to stop the embedded one from popping out, even if it comes loose.
Hanging from a guitar strap and resting on my hip put more strain on the case than sitting it on a tabletop. I may add some right-angled aluminium to stiffen the lower case but I'd like to find a lighter way to achieve this. Maybe just adding more plywood along each side and a diagonal piece or wire might work? Anyone else messing with these or other ideas for toughening the case up a little?
If I wasn't hanging the thing off me or folding it and otherwise lugging it around, I think it would be sufficient to just have a good light hard-case with squishy foam inside and just take it out once you get to the gig.
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Post by rodney on Jan 17, 2020 10:07:36 GMT
Great to see! Carsten had the idea to mount a rod in the middle of the hinge part between both hinges and get a carrying handle by this. Looks like your thing goes in this direction too! I'm open to make this as a variant if it's ok for you rodney ? Sure! It's just a variant on what you have anyway.
I hope to get a basic handle happening over the weekend so I'll report back.
I'm going to try wooden dowel with heat-shrink around it. However, bare or black-stained wood might feel nicer.
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Post by rodney on Jan 18, 2020 23:20:21 GMT
So .... I made up a rough handle yesterday.
It is very wobbly and does not do exactly what I am aiming for.
I may stick with this until my gig at the end of the month so I can actually work on what to play etc.
Some kind of locking mechanism would be good. I keep forgetting to allow for gravity and it always comes back to bite me. Standard AE modules are very light whereas random other devices attached with cable-ties weigh things down more and exceed the intended stresses for which the case is designed.
It's easier to pick it up and move it now but it is still awkward. I figure I'll try to work with this configuration for a while and see what other unforeseen stuff comes up.
I will add some other wooden brackets for the lower part in the last picture to keep it neater and safer. Keeping the thing safe is first priority, then I'll try to refine it for more comfort and convenience.
I hope this is helpful. It's not so much a how-to as a how-not-to. For DIY, I want to encourage people to try this kind of fast and dirty prototyping approach. It is easy to fall into the trap of aiming for perfection and never getting around to actually doing it because the optimal materials, tools, time and other conditions never quite line up. "Fail early and fail often" is a quote that reminds me to do things this way.
I reckon that the slightly longer case joiner without the handle extension works quite well with standard AE modules and lightweight DIYs. I'd add some rubber washers to increase friction as Robert has done with his.
I'm trying to constrain myself to the existing screw fittings on the case but I may finally crack and start drilling holes, if I don't find a more elegant solution.
As it stands (and falls), this prototype is a highly usable failure, as will be the next, but even more so ... |
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Post by thetechnobear on Jan 19, 2020 13:33:54 GMT
Cool stuff - for the folding case design this is what I really would like Perhaps a simple ‘latch’ mechanism for the handle could add the necessary stability eg something like how deck chairs/sound loungers work. |
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Post by rodney on Jan 20, 2020 0:56:25 GMT
Cool stuff - for the folding case design this is what I really would like Perhaps a simple ‘latch’ mechanism for the handle could add the necessary stability eg something like how deck chairs/sound loungers work. Yes, I'm starting to draw up some ideas for spring-loaded catch thingies. I'm trying to resist adding complexity but I think it will be needed. I'm also trying to resist using tougher materials such as aluminium because they do not bend, causing extra stress on the bendy AE case and materials. I may mess with sheets of HIPS or other tough but flexible plastics.
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Post by rodney on Jan 20, 2020 1:39:32 GMT
aaaand ... Just added some pieces of ply to the other end for transport. This makes it feel less wobbly when carrying it around.
However, as you can see, the Novadrone board pokes out the 'bottom' end when I'm carrying it by the handle so I can't simply put it down like a suitcase. However, a more 'normal' AE setup with proper-sized DIY modules would not have this problem. Also, to make it easier to open without removing the screws each time, I made a slot in one end of the plywood piece so it's just a matter of loosening the screw instead.  |
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Post by rodney on Jan 20, 2020 2:04:54 GMT
The bad news is that, as I have said earlier, the M5 nuts embedded in the acrylic case end pieces are designed to be fine for lightweight AE modules in a desk-based ( or closet-based!)home-studio context.
So ... stresses in odd directions are going to eventually pull them loose.
So far, I've just roughened and cleaned all surfaces before re-inserting the M5 nut with cyanacrylate glue (superglue). This is holding well so far but I plan to get it stronger by making longer fastening bolts and gluing a steel washer and another M5 nut inside the case (taking care not to interfere with any of the electronics).
If you are trying any of this crazy stuff, be aware that this is a weak point and I'm stressing the AE case in ways that were not part of its original design. From this perspective, I'm really impressed how strong the case is, given the focus on low price and weight. It survives abuse by being flexible but, I'd advise not to abuse it too enthusiastically. |
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Post by rodney on Jan 20, 2020 4:43:02 GMT
Do I need to clarify that it is not a fault of the AE case design? They are exactly how they should be, given the objectives driving their design.
Put another way ...
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Post by NightMachines on Jan 20, 2020 8:22:21 GMT
Loving this thread  If I remember correctly, very early on, Robert mentioned that he thought of the AE Modular as an affordable studio instrument and had designed it for this purpose specifically. But now we’re going crazy, creating our weird Frankenstein systems and lugging them around, hahaha! So I think it’s okay if we then also have to find our own ways to make the cases more rugged for travel and performance, like you’re doing here rodney. Really looking forward to you upcoming designs around the system! They’re very inspiring! |
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Post by spacedog on Jan 20, 2020 10:30:19 GMT
Loving this thread If I remember correctly, very early on, Robert mentioned that he thought of the AE Modular as an affordable studio instrument and had designed it for this purpose specifically. But now we’re going crazy, creating our weird Frankenstein systems and lugging them around, hahaha! So I think it’s okay if we then also have to find our own ways to make the cases more rugged for travel and performance, like you’re doing here rodney . Really looking forward to you upcoming designs around the system! They’re very inspiring! Mine gets a blanket and a bowl of warm milk every night... Nice to see them getting out and about.
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Post by rodney on Jan 20, 2020 11:58:07 GMT
Trying to find the most minimal way to achieve my desired result turns out to be more maximal than perhaps simply encasing the whole thing in metal! |
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Post by rodney on Jan 21, 2020 0:35:21 GMT
One thing I meant to note earlier is that the ribbon cable with two IDC 2x5 headers, provided with the case joining kit, are too short.
For this particular setup, I'm not using any AE modules in the 2nd case. However, I notice that the ribbon cable can be a little short, even with the standard AE case joiners.
I'll add a bit more tomorrow or the next day. Today, I have to wait for some superglue to dry. 
... and I have to spend some time figuring out how to make music with AE and the Novadrone (that will dutifully appear in another channel).
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Post by spacedog on Jan 21, 2020 9:21:30 GMT
This is really interesting, thanks rodney. Whilst I don't need to wear my modular, having a more robust method of storing it in a closed position is really interesting. In my mind, I was seeing something that was hinged, but with a greater stand-off distance, so that it might be possible to leave it patched with no dange of damage. As I have one old case and one new one, I would also need to be inventive (unless I break my resolution about the extra case ). The picture that I've seen of you me think of this - in a very good way (and that synth is very much in the NAMM news at the moment). I love the idea of getting out there with this equipment, and how I've seen you playing it is really amazing. |
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Post by rodney on Jan 22, 2020 10:15:31 GMT
This is really interesting, thanks rodney . Whilst I don't need to wear my modular, having a more robust method of storing it in a closed position is really interesting. In my mind, I was seeing something that was hinged, but with a greater stand-off distance, so that it might be possible to leave it patched with no dange of damage. As I have one old case and one new one, I would also need to be inventive (unless I break my resolution about the extra case ). The picture that I've seen of you me think of this - in a very good way (and that synth is very much in the NAMM news at the moment). I love the idea of getting out there with this equipment, and how I've seen you playing it is really amazing. One of my three favourite Edgars of all time (the others being Varese and Poe)
I am planning another case adventure involving doing some elaborate origami with coreflute fastened to a single AE case using the M5 threaded inserts at both front and back of the case.
However, a hinged lid, that protects a pre-patched panel but folds underneath to angle it for rockstarness, would be rather dope methinks.
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Post by rodney on Jan 22, 2020 10:27:13 GMT
Because I can't let too much time go by without a post here...
I bought some heat-shrink tube from an electronics hobby store and added a classy rubber(ish) finish to the handle to stop the artiste getting splinters.
tip: my mini gas heat tool was too small for this job and the hairdryer lacked the wattage to make the magic happen so I boiled up a kettle and poured boiling water over it, then I had a cup of tea.
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Post by rodney on Feb 1, 2020 9:58:40 GMT
I found the wire cable stays were not so strong and pulled the inserts out pretty easily.
So, I decided to make some aluminium struts instead to get me through the gig last night.
This keeps the two cases rigid enough to hang from a guitar strap. I also slightly modified the plywood case joiners so they lock to the m3 screw next to the M5 bolt (no image yet though)
here are the aluminum stays:
... and here they are mounted on the case:
That got me through the gig without crashing to the floor but I intend to make something a bit more rigid before the next one.
When I do, I will, of course, dutifully share it here.
Note in the photo that both the AE and the Novadrones are running off 10 rechargable 1.2v AA batteries. I have not tested how long that actually lasts but I'm sure that lithium batteries would give me more stamina per weight. The AE wil run on 12v instead of 9v as long as there is not too much current being drawn at once. The Korg effects thingy has its own set of 4 AA batteries and the TE PO-32 drum synth has its own pair of AAA batteries that seem to last for ages.
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Post by spacedog on Feb 1, 2020 10:15:02 GMT
I found the wire cable stays were not so strong and pulled the inserts out pretty easily.
So, I decided to make some aluminium struts instead to get me through the gig last night.
This keeps the two cases rigid enough to hang from a guitar strap. I also slightly modified the plywood case joiners so they lock to the m3 screw next to the M5 bolt (no image yet though)
here are the aluminum stays:
... and here they are mounted on the case:
That got me through the gig without crashing to the floor but I intend to make something a bit more rigid before the next one.
When I do, I will, of course, dutifully share it here.
Note in the photo that both the AE and the Novadrones are running off 10 rechargable 1.2v AA batteries. I have not tested how long that actually lasts but I'm sure that lithium batteries would give me more stamina per weight. The AE wil run on 12v instead of 9v as long as there is not too much current being drawn at once. The Korg effects thingy has its own set of 4 AA batteries and the TE PO-32 drum synth has its own pair of AAA batteries that seem to last for ages.
I must say that there is maximum admiration comin' right atcha from me 🙂 That's quite the rig and wearing it as well... Wow. |
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Post by rodney on Feb 1, 2020 10:53:10 GMT
I must say that there is maximum admiration comin' right atcha from me 🙂 That's quite the rig and wearing it as well... Wow.
Not too heavy either. I'll swap out the novadrones and Kaos Pad when a few more modules arrive in the mail and I get some DIY ones going.
Kl(aüs) were great live by the way. After I played, they put their new vinyl on a turntable on a plinth, under a spotlight, and we heard both sides. After that, they did a long improvised set on their synths with lots of actual playing of keyboards and general noodling. Stew's collection of lava lamps featured as well.
Most of their recorded material comes from leaving the multi-trak recording while improvising then going back and refining it.
Sadly, I was too disorganised to record my set this time. I will try to record something next week.
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Post by rodney on Apr 25, 2020 2:58:38 GMT
Another episode.
I rebuilt the handle-stand thingy.
I stained it with black Japan woodstain. I think it does a good job of hiding the dumpster origins of my plywood.
Now, I have a 5mm hole to fit over the m3 bolt head to hold the lower rack unit on an angle on the desktop (or against my body when playing standing up). When packing it up to carry, I loosen up the nut on the left so the hole can slip over the bolt head then I tighten it again on each end of the instrument.
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Post by rodney on Apr 25, 2020 3:10:01 GMT
Also, a pointed design lesson about affordances...
Affordances are a term that came into design from ecological psychology via design writers like Donald Norman.
In a nutshell, an affordance is what an object seems to want you to do with it. A handle on a teapot affords holding and lifting etc.
By putting the aluminium struts on in this way, and leaving the synth sitting on its side, I accidentally created an affordance for absent-mindedly using the struts as a handle to pick it up. very convenient but ...
Unfortunately, when picked up, they bend and flex enough to bend the acrylic enough to snap the acrylic.
So, more superglue and I need to find a way to take the strain off. Even a metal washer would do, but I may make something longer to distribute the force along the length of the acrylic sides. At the other end of the strut, the acrylic is protected by the wooden bits I added to hold the halves together when folded.
My lovely red and black rack case is starting to look a bit shabby but, *sigh*, it's a learning process...
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Post by rodney on Apr 25, 2020 3:22:10 GMT
I decide to add my Korg SQ01 into the empty rack space because one can never have too many sequencers, am I right? 
It weighs a tonne, so I removed the outer case of the Korg unit and un-soldered the battery connection. I tried unsuccessfully to wire it straight into the AE 5v supply but it seems to go better via USB. That will do for now. I'll find a neater way to power it later. 
I used my usual chopped up strips of PET bottle to mount it to the rear screws.
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Post by arti on Apr 25, 2020 16:12:07 GMT
aaaand ...
However, as you can see, the Novadrone board pokes out the 'bottom' end when I'm carrying it by the handle so I can't simply put it down like a suitcase. However, a more 'normal' AE setup with proper-sized DIY modules would not have this problem. Don't know if it's still relevant, but I would suggest to make a bit wider plywood, wider than Novadrone board, then You would be able (with wider plywood on both sides) to put it down. Love Your project! |
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