View Full Version : Built a chiller
i_jester
08-12-2004, 05:25 PM
After reading and watching all the activity with the A/C chillers around here, I wanted to do one also - here is how I did it and what I learned.
First thing I did was buy a 5150 btu a/c unit from Sears for $69.
I took it home and dissasembled it. Notice the first problem - the evaporator pipes enter the left side at the middle instead of at the top.
i_jester
08-12-2004, 05:27 PM
I then cut off the evaporator fan (The squirrel cage one) and was left with the pic below.
I had some aluminum left from another project and thought maybe I could make the reservoir with aluminum.
i_jester
08-12-2004, 05:28 PM
Here is the beginning of my brazed aluminum reservoir. After getting halfway through it, it became too problematic and I decided to go with copper.
i_jester
08-12-2004, 05:31 PM
My idea for the reservoir was simply to make a fairly tight copper box that would fit around the evap and add some barriers to force the water to flow back and forth a few times passing through the evap to maximize heat transfer.
Karnivore
08-12-2004, 05:35 PM
Looks good, These step by step threads are excellent, make sure to keep us posted, looks great so far! :toast:
i_jester
08-12-2004, 05:58 PM
Here is the setup I use for brazing/welding/cutting metals. Picked it up used for $100.
i_jester
08-12-2004, 05:59 PM
I purchased .043 copper sheet 12" x 36" at http://www.onlinemetals.com for $40 and away we went.
Here I am bending the bottom (Top would be identical)
i_jester
08-12-2004, 06:01 PM
Here is the main body of the reservoir:
(All the bending was done on a standard bench vise with a light ball peen hammer and a flat sheet metal wrench)
When bending, I would work my way back and forth across the piece bending it a little bit at a time - maybe 4 passes total to get a 90 degree bend.
i_jester
08-12-2004, 06:03 PM
I wanted to be able to seal the reservoir to the cap tube and suction tubes so I put holes in the side of the reservoir where the existing lines could pass through, and be brazed/soldered to seal it after assembly.
i_jester
08-12-2004, 06:10 PM
Here is the reservoir after brazing the bottom and body together and the pipes in place. Had a heck of a time getting the evap and pipes to go in after brazing the reservoir together. I had to carefully bend one side back, slide it into place and bend it back.
Also not shown are the copper pipes I flattened slightly to slide in as the barriers to direct water flow. I inserted them and soldered them into place as shown in my evap diagram a couple posts up.
i_jester
08-12-2004, 06:19 PM
After all that, I ended up with a leak and had to fix it. I have a cheap vacuum pump ($20 at Schucks) and pressurized the reservoir overnight to test for leaks.
Then I bought 1/2" polystyrene insulation at Home Depot and made a box to fit around my reservoir leaving approx 3/4" to 1" of space. I filled the space as I went with the minimallly expanding foam insulation in a can.
When I was done, the reservoir holds 3 quarts and takes about 20-30 mins to pull it down to -20 to -30 or so depending on the ambient temps. Almost no condensation anywhere even when running in the garage and the air being almost 30 degrees.
The front panel is a piece of aluminum that I cut and wire brushed then riveted into the space where I cut out the original plastic grill.
Also, the unit is fairly small - 11 1/2" high, 15 5/8" wide, 14" deep.
i_jester
08-12-2004, 06:21 PM
Here is the right side where the pipes exit.
Top is return, bottom is the feed to the pump.
I want to thanks practically everyone in this forum for information and help to make this possible.:toast:
DocGolem
08-12-2004, 08:08 PM
Looks awesome! I bought the exact same a/c as you did and I'm on your #2 step.
Bought some insulation today and I am hoping on cutting up my cooler to get my evap inside in a few days; I keep putting this off.
That a/c is a beauty for $69!
oc_nightmare
08-13-2004, 02:17 AM
awesome chiller:D
what temps are u getting with that res?
Unseen
08-13-2004, 05:06 AM
really beautifull!
i_jester
08-13-2004, 05:24 AM
I am not sure about exact temps. Need to figure how to monitor the water temp.
Once I get the CPU Block I ordered I will hook it up and try it out and post the results.
can't wait to see wut kinda temps u get... looks very similar to the type of chiller that gary makes... u defiantly have some skills man...
:toast:
gkiing
08-13-2004, 08:56 PM
I'd just have to say awesome job, I like the res design how you designed the res around the evap instead of using a cooler.
Gary Lloyd
08-14-2004, 04:35 AM
Excellent work. Your evap/res is very similar to my TECHChiller #1, and your flow control is well thought out. It should be extremely efficient, handling every bit of heat your computer can throw at it with ease.
Good job. :toast:
nice that is a really good res design.
what mobo ya gona run with it.
could download mother board monitor for an estimate on temps
i_jester
08-23-2004, 07:54 AM
Next step in the project is at this thread:
Airtight Motherboard (http://www.xtremesystems.org/forums/showthread.php?s=&threadid=41154)
blinky
08-28-2004, 09:56 PM
same one i have, looks good man
:thumbsup:
o and report back the temps when u get a thermometer
i_jester
08-28-2004, 10:02 PM
Update:
Getting close to being able to test it. My CPU and last waterblock should be here by wed or thurs of this week.
WesM63
08-28-2004, 10:22 PM
i_jester,
You can get a fairly cheap temp sensor from radio shack. I picked mine up for $10.
BTW, Looks good, I completly skipped the waterchilling and went straight to phase ;)
Reflex1
08-28-2004, 10:57 PM
for a first build (i think?) thats awesome! i love the res/evap idea.
what pump u using?
i_jester
08-29-2004, 06:22 AM
Yes I am a watercooling and chilling virgin - so to speak.
This is the first time I have ever done any of this kind of stuff.
I am going to use an Swifty mcp650
i_jester
09-06-2004, 07:43 PM
New updates to the chiller project at:
http://www.xtremesystems.org/forums/showthread.php?s=&threadid=41154&perpage=25&pagenumber=2
i_jester
09-20-2004, 08:08 AM
OK, the whole chiller thing worked great.
Pulls the res (3 liters) down to -27c or so in 20 - 30 mins on a cool day. I have a P4 3.2c running at 16x250 (4ghz) and the BFG6800GT at 420/1110 and the liquid temps stay right around -20c or so under full load.
Very happy with the results, but time to move on. The building was all the fun, now I am going to sell it all and start something else - namely, building our new house.
Waus-mod
10-13-2004, 02:27 PM
Where can you buy these phasechange setups? : http://www.xtremesystems.org/forums/attachment.php?attachmentid=15376
And what are they supposed to be?
blinky
10-13-2004, 02:29 PM
Where can you buy these phasechange setups? : http://www.xtremesystems.org/forums/attachment.php?attachmentid=15376
And what are they supposed to be?
hey i have that one :D
its an air conditioner
they sell em at home depot
Waus-mod
10-13-2004, 02:31 PM
hey i have that one :D
its an air conditioner
they sell em at home depot
Are they expansive?
saratoga
10-13-2004, 03:57 PM
According to this thread, that AC cost $69.
Waus-mod
10-14-2004, 05:07 AM
69$, thats verry cheap, for a waterchiller
Crankster
10-14-2004, 07:50 AM
for an A/C unit, add to that the work you put in and such.
blinky
10-14-2004, 01:37 PM
According to this thread, that AC cost $69.cost me $79