Project: Aluchill[Scratch build]

http://bandwidth.se/imgs/39/226/logga.jpg




Sponsored by:
Alphacool
Sifvert
And a special thanks to Tom @ ChilledPC

Links:
Update #1 (Frame constructing and diy)
Update #2 (Frame finished)
Update #3 (Panel cutting)
Update #4 (Panel cutting & mockup)
Update #5 (Panel cutting & mounting)
Update #6 (Panel mouting, PSU opening, tray slide)
Update #7 (Back panel finished & WC stuff)
Update #8 (Shape complete, outer panel cut and bent)
Update #9 (5,25 Holder and diy)
Update #10 (Front Construcion)
Update #11 (Front Completed)
Update #12 (Rad mount and internal cover)
Update #13 (Fan grills and LCD-bezel)
Update #14 (Details before powder coat)
Update #15 (HDD-suspension and details)
Update #16 (Powder Coat & set back)
Update #17 (Finally! Assembly line)
Update #18 (Assembly continues)
Update #19 (EYE CANDY!)




About the project:

So guys, this is my first scratch build ever. I've always felt quite unpleased by modding a pre-made case so this should be very exciting.
As you have probably already realised by its name, this mod is going to be built using aluminum materials only. It's a nice material to work with, and its fairly light weight.
It is going to be packed with high-end water cooling and some nice components.

Hardware:
XFX 780i SLI motherboard
Intel QX9650 CPU
4x 1gb OCZ FlexXLC 9200 memory
2x 8800Ultra in SLI graphics cards
Corsair HX1000 power supply
Creative X-fi Fatal1ty Titanium sound card
WD 36gb 10k raptor
Samsing 400gb harddrive

Watercooling:
EK Supreme CPU
2x EK-FC8800 GTX/Ultra - Acetal
EK-NB 780i - Acetal
EK 780i Mosfet block
Thermochill PA120.2
Thermochill PA120.3
2x DDC3.2 with XSPC laing top
Feser compression fittings

So now it starts. Here are some pictures for you all.

Sketches:
http://bandwidth.se/imgs/39/226/aluchill1.jpg

http://bandwidth.se/imgs/39/226/1222.jpg

http://bandwidth.se/imgs/39/226/aluchill2.jpg

The motherboard tray. Produced by Lian-li. And of course it's made out of aluminum.
http://bandwidth.se/imgs/39/226/img6573.jpg

The water blocks I will be using.
http://bandwidth.se/imgs/39/226/parts.jpg

First I'm going to build the frame. It is going to be built using 15 x 15mm solid aluminum bars.
I'm going to join the bars using M5 hex cap screws.
The plan:
http://bandwidth.se/imgs/39/226/img7243.jpg

And after some cutting with the mithrill saw I got all the pieces I need. The cuts and the bars are very nice and straight.
http://bandwidth.se/imgs/39/226/img7242.jpg

In order to get the right angle I need, which is quite important when building like this, I'm going to use a 90 degree clamp.
http://bandwidth.se/imgs/39/226/img7244.jpg

I will drill the holes using this drill:
http://bandwidth.se/imgs/39/226/img7245.jpg

Start out with drilling the hole so that the hex screws will be counter sunk nicely into the bar.
http://bandwidth.se/imgs/39/226/img7270.jpg

Directly after drilling
http://bandwidth.se/imgs/39/226/img7271.jpg

And after that I drilled the hole for the screws thread.
http://bandwidth.se/imgs/39/226/img7272.jpg

Clamp two bars together like so:
http://bandwidth.se/imgs/39/226/img72740.jpg

Then manually drill the hole in the second bar which is going to be threaded.
http://bandwidth.se/imgs/39/226/img7275.jpg

Tapping for M5 bolts:
http://bandwidth.se/imgs/39/226/img7278.jpg

Some lubricant makes the process much easier:
http://bandwidth.se/imgs/39/226/img7276.jpg

Then screw the bars together with the hex cap screws and we get this:
http://bandwidth.se/imgs/39/226/img7280.jpg

Repeat this process 10 times and you have the top of the frame done
http://bandwidth.se/imgs/39/226/img7273.jpg

Repeat the process another 10 times and you have the basic frame done.
http://bandwidth.se/imgs/39/226/img7281.jpg

It is not finished yet though. Have some bars left to mount.

Got a package from Alphacool containing a nice little display

http://bandwidth.se/imgs/39/226/img7283.jpg
http://bandwidth.se/imgs/39/226/img7284.jpg

Thanks guys! Should suit this project perfectly!

Nice start:up:
I want more photos!;)

I love scratch builds, and yours looks like its gonna be an awesome project! Can't wait to see more! :up:

Thanks guys!
Can't wait to see more myself :D

I swear I've seen those sketch ups before O_____o I must be going mad.

Anyhoo fantastic project and I'm itching for more. MOOOAARRRRRRR

You probably have. Started a thread a while ago but never got any work done. Now when I finally have started to build, I wanted to start fresh so I created a new thread. :)

Ahhh ok. Well I LOVE the design [that's why I remember it].

great craftmenship, looks like this is going to be a good one!
Subbed

What do you plan on doing with the drive bays/psu slots?

Hey guys! Time for an update again.
Went to the workshop and spent a couple of hours finishing up the frame.

Got the part done for the middle floor. The floor will separate radiators and PSU from the main computer components.
http://bandwidth.se/imgs/39/226/img7286.jpg

Took a photo of a section of the frame with two joints. Just to give you a hint of what kind of precision this is.
http://bandwidth.se/imgs/39/226/img7287.jpg

And finally got all bars together and finished up the framework.
http://bandwidth.se/imgs/39/226/img7288.jpg

http://bandwidth.se/imgs/39/226/img7290.jpg

Next step will be to cut all the panels from this "little" piece of aluminum sheet.
http://bandwidth.se/imgs/39/226/img7291.jpg

All the bends will be worked out using this brand new brake.
http://bandwidth.se/imgs/39/226/img7292.jpg

Comments are welcome! :thumb:

I've always wanted to design my own case. Maybe sometime I will.

This looks great!

I always enjoy the fully custom builds...I'll be watching this one for sure!

Why not use all-aluminum watercooling gear as well?

or nickel plated copper :)

great so far... subscribed :up:

Fully custom builds are a challenge, but it looks like you have the right tools and motivation to do it right. This should be good!

:shocked:

SOLID ALUMINIUM FRAME *drool*

I can't wait to see this finished... the quality is outstanding.

Weigh it when it's done will you? I have a feeling it won't be light ;)

Nice work, custom builds are always the most impressive!

Reverse-ATX FTW!:cool:

looks cool nysoO, cant wait to see how you do with it :up:

subbed :cool:

Hey guys. Got some time to work on the project so here is an update for ya.

I laid the sheet metal on top of my workbench in order to be able to work with it.
http://bandwidth.se/imgs/39/226/img7300.jpg

Going to cut out some panels using this jigsaw
http://bandwidth.se/imgs/39/226/img7317.jpg

New blades for cutting in metal
http://bandwidth.se/imgs/39/226/img7316.jpg

I problem that I ran into was how to make the cuts as perfect as possible. In order to solve this I took a straight piece of wood and clamped it on top of the panel. Then I just followed the wood with the jigsaw. Think it worked pretty damn good.
http://bandwidth.se/imgs/39/226/img7308.jpg

Like so:
http://bandwidth.se/imgs/39/226/img7302.jpg
http://bandwidth.se/imgs/39/226/img7303.jpg

And after some sanding and filing to smooth up the edges I got this:
http://bandwidth.se/imgs/39/226/img7304.jpg
Pretty good huh?

http://bandwidth.se/imgs/39/226/img7305.jpg
http://bandwidth.se/imgs/39/226/img7306.jpg

Got two of them :)
http://bandwidth.se/imgs/39/226/img7318.jpg

Just need to saw out the other panels which probably wont take too much time.
Made a little video for you showing the process of the sawing:
http://www.youtube.com/watch?v=kY2Fn-B4U6E
What do you think?

Btw, how do you change the main title? It says Oct 31 but it's supposed to be Nov22 .. of course

you're doing a very good job.

continue that!

Quote:

---

Originally Posted by NysoO

Btw, how do you change the main title? It says Oct 31 but it's supposed to be Nov22 .. of course

---

you can't. :( You have to PM an admin.

Love the build and <3 your workshop moar! Are you kidding me? I thought that was your school workshop from the last build? BTW, what's happening with your other build (which to be honest inspired me with the door cut out for my own) Water Inside?

deff subb'd!

Awesome workshop and build!

I'm like it :)