Mon Feb 19, 2018 9:24 pm
The plastic cans that Rob sells work fine. They just need to be machined. If you have access to a CNC mill, it should be fairly easy to cut.
If I were going to cut them manually:
1) Get a flat piece of plastic, maybe 1/4" to 1/2" thick(just needs to be thick enough not to flex)
2) Trace a circle the size of the interior of the new can
3) Trace the cut out of the original can into this circle(center it, etc)
4) Cut these shapes out with a dremel or router. Keep the cut square
5) Glue it with something temporary to the inside of the new can( pay attention to the location of the mounting tabs in relation to the horn)
6) Using the normal bolt holes, screw or bolt the can to some wood(vibration is your enemy and will shatter it)
7) Using the skinniest flush trim router bit you can find, set the depth so that you are only cutting the can material(see youtube if you aren't familiar with a flush trim bit)
8 ) Slowly cut it out
9) Remove the template
10) Using a small file, clean up the corner of the tabs so that your body fits the new can. Also, clean up any loose plastic edges
11) Dive it like you stole it
"Haul the sheet in as we ride on the wind that our
forefathers harnessed before us
Hear the bells ring as the tide rigging sings.
It's a son of a gun of a chorus" - Jimmy Buffet