Enclosure

The enclosure is a waterproof plastic box from Maplin. It's about 150x110mm by 70mm high.





Fan

The 120mm fan runs on 12V and draws about 300mA.





Fan Adapter

The 120mm fan is too big to fit onthe box, so this reducer goes between the two. It fits an 80mm fan at one side, and the 120mm on the other.





Cutting the lid.

The lid was held onto a rotary table on a milling machine using lumps of Blu-Tac (there wasn't enough room on the 150mm table to get clamps to work). The lid material is quite soft, and several passes at a slow rotation speed didn't dislodge it.





Almost through

The cutter has broken through the surface of the lid.





Hole made

The hole has been completed and the waste disc has fallen down.





The assembled extractor

The extractor has been assembled. Inside, there is a 100mm square piece of mild steel plate, about 10mm thick, held in using hot melt glue. This gives weight and stability. The hose is attached to the extractor using a tank (or bulkhead) fitting which screws into a hole in the side of the case. On top of the fan is a carbon impregnated filter sold as a spare for a budget level commercially made extractor.





Fume extraction pipe

The extraction pipe is made from 250mm of 25mm diameter aluminium tube. The grey hose connecting the extractor and the tube is a standard washing machine waste pipe. The multi-position vice was already available - I may make a proper stand sometime (or just buy another vice...).