Sonic Impact T-Amp Enclosure

In designing a new enclosure for my modded T-Amp, I wanted something unique, low cost, small footprint and fairly easy to build. Here is what I came up with. The raw materials consist of: 1. 80/20 Series 2040, 2" x 4" x 5.5", clear anodized extrusion 2. .125" aluminum sheet 3. 2" x 4" Corian solid surface material - color Slate The extrusion is the 80/20 industrial extrusion available directly from 80/20 on eBay. It's pretty cheap stuff for this size of application. The Corian I used are samples directly from Corian. I purchased 1 piece of 6" x 8" Slate for my project. They are about $5.50 plus shipping. The only downside - there are only a handful of colors to choose from in the 6" x 8" size. You can also check on eBay. There are several people selling Corian (and similar) cutoffs on eBay. To create the enclosure I removed a section of the extrusion - as seen in the image. This requires a table saw in order to do it correctly. It's not hard to do, but you must take extreme caution in doing this. Safety first! You might notice that the rear connectors look like they're touching the case. They are not, but it's close. So, I'm going to add some Kapton tape - just for peace of mind. Once the section is removed, there will be an area for the bottom plate to slide into. Next step is to cut the bottom plate from the .125" aluminum. The image shows how the bottom fits into the extrusion. Notice how everything fits quite nicely in the enclosure - although the off-board 2.2uF Solen input capacitors were not installed yet. to be continued....