Built a chiller

[i_jester]

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]

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]

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]

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]

Looks good, These step by step threads are excellent, make sure to keep us posted, looks great so far! :toast:

[i_jester]

Here is the setup I use for brazing/welding/cutting metals. Picked it up used for $100.

[i_jester]

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]

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]

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]

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]

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]

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]

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]

awesome chiller:D
what temps are u getting with that res?

[Unseen]

really beautifull!

[i_jester]

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.

[OCme]

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]

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]

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:

[kayl]

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]

Next step in the project is at this thread:

Airtight Motherboard (http://www.xtremesystems.org/forums/showthread.php?s=&threadid=41154)

[blinky]

same one i have, looks good man

:thumbsup:

o and report back the temps when u get a thermometer

[i_jester]

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]

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]

for a first build (i think?) thats awesome! i love the res/evap idea.

what pump u using?

[i_jester]

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]

New updates to the chiller project at:

http://www.xtremesystems.org/forums/showthread.php?s=&threadid=41154&perpage=25&pagenumber=2

[i_jester]

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]

Where can you buy these phasechange setups? : http://www.xtremesystems.org/forums/attachment.php?attachmentid=15376

And what are they supposed to be?

[blinky]

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]

hey i have that one :D

its an air conditioner

they sell em at home depot

Are they expansive?

[saratoga]

According to this thread, that AC cost $69.

[Waus-mod]

69$, thats verry cheap, for a waterchiller

[Crankster]

for an A/C unit, add to that the work you put in and such.

[blinky]

According to this thread, that AC cost $69.cost me $79