[rcheshire (Rowland)]

Just finished fabricating a cold finger to fit a Canon 450D. It will also fit the 1000D, and from what I can see, the 500D.

The CF fits around all the hardware, except for the side cover on the USB/video port side of the camera - unless the camera owner is happy to remodel it - tape is just as effective and less destructive.

The zip/.dxf file is the template shown in the images.

Materials - 1.2mm copper sheet.

Tools - bench vice, centre punch (optional), steel rule, scoring tool, drill and 2, 3 and 4mm bits and a small file.

Method of working - print template, check template for correct scale, cut out and fix to copper, scribe outline and cutouts and fold lines, centre punch holes.

Drill 2mm mounting holes - these align with the sensor frame 2mm tapped holes.

Drill out cutouts with 2, 3 and 4mm drills, file square.

Bend as instructed on template and keep them tight. Most important - the two middle bends when complete should be no deeper than 5mm, one side to the other, as shown.

I cut out the notch in the wrong position and had to widen to fix - access to sensor ground connection screw.

EDIT: The bends are easy enough to do in a bench vice. Line up the score mark with the top edge of the vice. Place a flat metal/wood plate behind the copper to apply even pressure (don't use thumbs and fingers). Bend to right angle. The middle bend can be a fiddle. A spare bit of 3mm aluminium plate placed between and flush with the top of the vice jaws, slightly longer than the sensor end to avoid crushing it, as shown. It's important to clamp the copper both sides to get a good sharp bend. Radii on the bends don't work - the finger won't fit.