09/10 Project

Hi people, I'm not much for words (hence the post count) but I check these forums religiously every day and thought it was about time i contributed something :).

I've gathered plenty of knowledge over the last couple of years, looking at the water cooled case gallery and worklogs, and figured i may as well share my latest project.

I'd also like to point out that I've started this project back-to-front compared to most, starting with a case, then modding the hell out of it (lol), and lastly buying all the hardware (aside from some of the w/c gear which i purchased earlier to get an idea of certain dimensions and space factors).

So, i chose a Lian-Li PC-A10 as the chassis. This is mainly because i like the layout and size, and at the time i had one to take measurements and such from while the fresh one came in the post. I ordered the standard aluminum coloured case under the impression it hadn't already been anodized and I would be able to anodize certain panels black after it was water jet cut. i later found out that the case is actually still anodized, only it's clear, so i guess the whole thing's gonna get powder coated instead.
To make things worse, the case came 3 months late (friggen customs!) and came with handles bolted on as it was the last silver case ppc's had. So I've had to make some adjustments.

All the internals have been re-cut, bent and drilled as you'll see in the following pics. This was to allow more space behind the mobo tray and get rid of the holes in the centre divider. i also wanted to remove all unnecessary drive bays to make the case more roomy.

I'll also point out that i'll be using a simple point and shoot camera so there won't be any of these fancy pants crazy lighting shots, although i did use a tripod which helped.

Anyway, I'll be quiet now and show some pics -

This is the case (not my pics though)

http://i227.photobucket.com/albums/d...09/PC-A101.jpg

http://i227.photobucket.com/albums/d...09/PC-A102.jpg

http://i227.photobucket.com/albums/d...09/PC-A103.jpg


These are the parts i had water jet cut -

http://i227.photobucket.com/albums/d...9/IMG_1321.jpg

Side Panels
http://i227.photobucket.com/albums/d...9/IMG_1322.jpg

Faceplate
http://i227.photobucket.com/albums/d...9/IMG_1333.jpg

http://i227.photobucket.com/albums/d...9/IMG_1324.jpg

Drive Cage Part 1
http://i227.photobucket.com/albums/d...9/IMG_1326.jpg

Drive Cage Part 2
http://i227.photobucket.com/albums/d...9/IMG_1329.jpg

Centre Divider
http://i227.photobucket.com/albums/d...9/IMG_1328.jpg]

PSU Bracket
http://i227.photobucket.com/albums/d...9/IMG_1330.jpg

Mobo Tray
http://i227.photobucket.com/albums/d...9/IMG_1331.jpg

Backplate
http://i227.photobucket.com/albums/d...9/IMG_1332.jpg



I needed to cut a hole in the top for a res i'll build and another hole in the front for a faceplate -

Top:

http://i227.photobucket.com/albums/d...9/IMG_1338.jpg

http://i227.photobucket.com/albums/d...9/IMG_1339.jpg


Used this next (laminate trimmer + carbide bit) to give a nice, straight cut -

http://i227.photobucket.com/albums/d...9/IMG_1454.jpg


See -

http://i227.photobucket.com/albums/d...9/IMG_1341.jpg


Last step was the corners. This was done with a small flat file -

Left Corner
http://i227.photobucket.com/albums/d...9/IMG_1382.jpg

And Right Corner
http://i227.photobucket.com/albums/d...9/IMG_1383.jpg


Now the face -

http://i227.photobucket.com/albums/d...9/IMG_1342.jpg

http://i227.photobucket.com/albums/d...9/IMG_1343.jpg


I wanted the faceplate to be made of brushed aluminum and i would later anodize it black (Can you guess where i got the idea? A guy called charles comes to mind)

Anyway here's how I brushed it for anyone interested -

http://i227.photobucket.com/albums/d...9/IMG_1368.jpg

http://i227.photobucket.com/albums/d...9/IMG_1369.jpg

http://i227.photobucket.com/albums/d...9/IMG_1371.jpg

http://i227.photobucket.com/albums/d...9/IMG_1374.jpg

http://i227.photobucket.com/albums/d...9/IMG_1375.jpg

http://i227.photobucket.com/albums/d...9/IMG_1376.jpg

http://i227.photobucket.com/albums/d...9/IMG_1377.jpg

http://i227.photobucket.com/albums/d...9/IMG_1378.jpg

http://i227.photobucket.com/albums/d...9/IMG_1362.jpg

http://i227.photobucket.com/albums/d...9/IMG_1365.jpg


While it's obveously not up to the same standard as charles work, it still fits and, in the very least, it's something different so i'm happy. It will also sit more flush once the brackets are made....hopefully.


I started on the internals next -

Mobo tray -

http://i227.photobucket.com/albums/d...9/IMG_1344.jpg


Now drilled, tapped and fitted with a test board (i don't have any action pics of this sorry). I kept the pci-card-holder-thingy from the case as there was no point trying to redesign it. Luckily everything fits -

http://i227.photobucket.com/albums/d...9/IMG_1349.jpg

http://i227.photobucket.com/albums/d...9/IMG_1350.jpg

http://i227.photobucket.com/albums/d...9/IMG_1351.jpg


Some small adjustments to help it fit inside -

http://i227.photobucket.com/albums/d...9/IMG_1458.jpg

http://i227.photobucket.com/albums/d...9/IMG_1459.jpg


Drive cage -

http://i227.photobucket.com/albums/d...9/IMG_1353.jpg

http://i227.photobucket.com/albums/d...9/IMG_1354.jpg

http://i227.photobucket.com/albums/d...9/IMG_1360.jpg

http://i227.photobucket.com/albums/d...9/IMG_1363.jpg




Next is the res -

This is a trial run. The real thing will be laser cut and some dimensions will change slightly but i needed to do this to find out how much room i had to play with.

I decided to build a routing tabletop for this job and mounted the laminate trimmer upside down under an aluminum plate i bought and shaped -

http://i227.photobucket.com/albums/d...9/IMG_1386.jpg

http://i227.photobucket.com/albums/d...9/IMG_1387.jpg

http://i227.photobucket.com/albums/d...9/IMG_1388.jpg



Res top -

I started with a piece of acrylic and cut it to size, after which i routed off 16.5mm from the side edges @ 1.5mm deep and, 14.15mm from the top and bottom edges also @ 1.5mm deep. The pics will help make sense of what i mean, and by doing this it will allow me to mount the res under the roof of the case while still being flush with the top of the case outside (if that makes sense :shrug:) -

http://i227.photobucket.com/albums/d...9/IMG_1389.jpg

http://i227.photobucket.com/albums/d...9/IMG_1391.jpg


One of the ends had to be routed and extra 1.5mm deep to allow for a reinforcement layer of aluminum at the back of the case which can't be removed -

http://i227.photobucket.com/albums/d...9/IMG_1394.jpg



Sides -

http://i227.photobucket.com/albums/d...9/IMG_1399.jpg

http://i227.photobucket.com/albums/d...9/IMG_1401.jpg

http://i227.photobucket.com/albums/d...9/IMG_1402.jpg

http://i227.photobucket.com/albums/d...9/IMG_1404.jpg


Watch your finger(s) -

http://i227.photobucket.com/albums/d...9/IMG_1409.jpg


After that little mishap i made some adjustments -

http://i227.photobucket.com/albums/d...9/IMG_1411.jpg

http://i227.photobucket.com/albums/d...9/IMG_1412.jpg

http://i227.photobucket.com/albums/d...9/IMG_1413.jpg

http://i227.photobucket.com/albums/d...9/IMG_1414.jpg

http://i227.photobucket.com/albums/d...9/IMG_1417.jpg

I think you get the gist.


The top and bottom ends were a little harder to get square... so i used a square -

http://i227.photobucket.com/albums/d...9/IMG_1420.jpg


In the end it worked out pretty well, only a out by 100th of a mm

http://i227.photobucket.com/albums/d...9/IMG_1425.jpg


I routed the corners too far with a 45 degree chamfer bit which was a bummer but it turned out ok in the end. Its a test anyway -

http://i227.photobucket.com/albums/d...9/IMG_1429.jpg


And, because of the 1.5mm routing around the edge of the top, the res now sits flush with the surface of the case top...or atleast it will once it's secured there -

http://i227.photobucket.com/albums/d...9/IMG_1433.jpg

http://i227.photobucket.com/albums/d...9/IMG_1430.jpg



So here's the project up to date -

http://i227.photobucket.com/albums/d...9/IMG_1434.jpg

http://i227.photobucket.com/albums/d...9/IMG_1439.jpg

http://i227.photobucket.com/albums/d...9/IMG_1440.jpg

http://i227.photobucket.com/albums/d...9/IMG_1441.jpg

http://i227.photobucket.com/albums/d...9/IMG_1442.jpg

http://i227.photobucket.com/albums/d...9/IMG_1443.jpg


Loads and loads of work left so please don't judge on first impressions :up:


That's all for now, thanks a bunch for looking. It's going to be a while before i update this thread again as I'm trying to get some hi-temp metal putty shipped in before i proceed but I'm having a hell of a time getting it, so please, don't hold your breath :).

Cya people,
Callen

Oh my, this is going to be something SPECIAL!

TOP work mate, the res is amazing!

Very nice job on that metalwork. Nice, clean cuts. Looking great! Really liking your attention to detail.

Wow, this is going to be amazing! great work!! :up:

Looks very nice so fare :D looking forward to final result :)

Very nice work, case is lookin spacy at this moment ... :P

It looks a lot like an antec p182, but with the lian li quality ...

awesome work so far...
and then, what's gona have the priviledge of working inside?? core i7 I guess???

outstanding job dude

Looks good so far.

Only one thing, are you anodising the case, the brushed alu fronts dont match so it needs to be fixed.

Absolutely Amazing!

I was having one of those days and then came here and saw this project - truly inspiring stuff. Seeing creativity and workmanship at this level is an absolute joy to behold.

You Sir, made my day - I look forward to your next update. :)

Amazing metal work, love the front panel.

Wow :shocked:

I that is some seriously awesome craftsmanship! I can't wait to see more progress.

Haven't been on much today - missed this one. Whoa - only one word to describe your project - Awesome !!!

WOW:eek: love the metalwork

I Can't Wait FOr More Pic Pleasssse :) :) :)

All I can say is that this project has Million Dollar PC (MDPC) written all over it.

This is incredible. Instantly became my #1 favorite build - one of the ones I truly can't wait to see updates for.

Someone get this man some hi-temp metal putty, stat!

So i'll start with a big thanks for the complements from everyone, i'd be lying if i said that i wasn't hoping for a couple :P

As far as pics go, I could post a couple of the usual (sleeving and tubing and what not) but i'm going to stick to major updates.
That way it will make your visit a little more worthwhile.

I was actually a little resilient to start this log as it's taken quite some time to get this far, but now that i've finally started it,
it should kick my lazy ass into gear, and i'll hopefully get a lot more work done.

Scubar; only the faceplate and a couple of other brushed aluminum pieces (which will later be used inside the case) are going
to get anodized. the rest of the case is will be powder coated black, which will include the side panels unfortunately although i
wanted them to be anodized too.

Lastly Charles; i hope your day is a little better, and Antioch; i wouldn't even mention the word million in this thread until it's 99%
complete and somehow curing cancer lol, but thanks nonetheless :up:

Cheers again guys,
Callen

Computers have been known to assist in the development of cures for other diseases, such as Leukemia and Lymphoma via auctions. :)

It's been said but bears repeating, your metal-working skill is awesome. I really dig the panel designs, too. This worklog just kinda sprang (sprang? sprung?) outta nowhere with a slew of down-and-dirty photos, I'm starved for more. Keep it up!

Heh, alright, alright - sorry. Ehrm, Thousand Dollar PC perhaps?

Honestly it looks like it will be a great case. I'm just imagining everything all black and spiffy in my head right now, but my imagination is terrible so you need to hurry up and finish it so my eyes can see it ;)

Good luck!

Quote:

---

Originally Posted by Kibbler

Computers have been known to assist in the development of cures for other diseases, such as Leukemia and Lymphoma via auctions. :)

It's been said but bears repeating, your metal-working skill is awesome. I really dig the panel designs, too. This worklog just kinda sprang (sprang? sprung?) outta nowhere with a slew of down-and-dirty photos, I'm starved for more. Keep it up!

---

good point, i guess computers can cure disease...so maybe....no, please, don't put ideas in my head :).

Quote:

---

Originally Posted by Antioch

Heh, alright, alright - sorry. Ehrm, Thousand Dollar PC perhaps?

Honestly it looks like it will be a great case. I'm just imagining everything all black and spiffy in my head right now, but my imagination is terrible so you need to hurry up and finish it so my eyes can see it ;)

Good luck!

---

it's certainly a thousand dollar pc, hell, it's a thousand dollar case at the moment lol, u ever water jet cut anything? i had to re-mortgage my freaking car :P

Edit: re-mortgage obviously the wrong word here but i think you get the point

No I have never water jet cut anything. I'd love to have the opportunity but I don't know anyone with that kind of machinery :(

One thought - it may be a good idea to make the base of the rooftop water tank not level towards whatever end you place the tubing barbs since the tank is so shallow and wide. But, I suppose the dynamics of it all depend on how you actually place the tubes in and out. Didn't mean to throw any wrenches into the plan.

Quote:

---

Originally Posted by Antioch

No I have never water jet cut anything. I'd love to have the opportunity but I don't know anyone with that kind of machinery :(

One thought - it may be a good idea to make the base of the rooftop water tank not level towards whatever end you place the tubing barbs since the tank is so shallow and wide. But, I suppose the dynamics of it all depend on how you actually place the tubes in and out. Didn't mean to throw any wrenches into the plan.

---

The res is going to contain another chamber made of thinner 3 mm acrylic. I tried to design it so water will be sucked in from the bottom of the res to avoid air being pulled into the pumps, but whether it actually works or not is another story i guess.

Thanks for your thoughts though, it all helps.

How did you manage to bend the aluminum in 90-degree angles so cleanly?

Quote:

---

Originally Posted by josk1

awesome work so far...
and then, what's gona have the priviledge of working inside?? core i7 I guess???

---

Sorry mate, i skipped over your post by accident. But to answer your question, at this point in time i'm going to be putting in an i7 but it will be in a p55 board. This isn't completely by choice though. I'm waiting for reviews of MSI's "big bang fuzion" board with the lucid hydra chip, because if the chip scales graphics as well as it's supposed to it's gonna be awesome. The problem is this is the only mobo with the hydra chip integrated and it's an 1156 board, so no triple channel for me. The colour scheme is also exactly what i was looking for, which is another big factor.

Quote:

---

Originally Posted by Antioch

How did you manage to bend the aluminum in 90-degree angles so cleanly?

---

This was done with a metal press. I'd also like to point out that it was done professionally, i just had to mark out the bend lines on the metal and which way it needed to bend. I'd love my own press though, maybe one day. So sorry if i mislead anyone.

Lynnfield. I really hate what Intel is doing with the 32nm transition of Nehalem.

So, I guess you'll put 2 radiators in the basement? (I only saw one in the picture) What will be going in the front behind the faceplate? Judging from the hole you cut in the front end of the midplate it looks as if you can fit a 120.2 radiator in there as well... :)