This is amazing!
It's nice when things work out. Any luck with the resin? Oh no! I bet he's stuck somewhere!
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This is amazing!
It's nice when things work out. Any luck with the resin? Oh no! I bet he's stuck somewhere!
Thank you. I always bend on the center point of the radius, so I usually have to do a little math when I'm marking my material. You have to account for the thickness of the material as well. For example, if you want to make a 'U' shaped channel with 20mm between the sides, you can't just make marks 20mm apart and bend. You'd actually end up with less than that depending on the thickness of the material you are bending. If you are using 1mm material, you'd end up with 19mm. If you are using 2mm, you'd end up with 18mm. So, you have to account for the material thickness from the beginning, and mark accordingly.Quote:
Originally Posted by LogAn'sRun
As far as the angles go, I've got a gauge I can use to get things just right, but I've got a pretty good eye for angles. (I grew up with a dad who was a carpenter, and am pretty experienced with carpentry myself.) I can almost always get it right the first time, but adjust if needed.
Thank you Mike. Lol, I never thought about what a sawhorse might be called over there. ;)Quote:
Originally Posted by phinix_mike
Thanks man. You're right, I might wish I had box and pan too. Things do seem to get a little complex for me. Lol.Quote:
Originally Posted by Waterlogged
Thanks Wezly. I took a look at the resin this morning, and it's about 95% cured. It's still got a very slight tack. Not enough to dent or fingerprint, but just enough to let me know it's not completely cured. I've got no doubt about my ratio being correct. I'm going to assume it's just a little humid in the basement and see how it looks tonight. I also may need to raise the temp a little bit. The hardener I'm using has a sweet spot between 80 and 85 F, any lower and curing may be affected. There's no way I'm going to wrap until I know the resin will work perfectly.Quote:
Originally Posted by Wezly
Ready guys?
Well, working with the carbon fiber was an interesting experience. I got completely prepped and ready to go last night, so that I could start wrapping first thing this morning. I'll admit to being a bit nervous. I didn't have any room for error, and with my OCD about having things perfect, the pressure was on.
I woke up this morning, headed to the shop, and cranked up the music. A little Zune Pass with Breaking Benjamin as the starting point, and things were underway! What you'll see here is the mold ready to go, with the carbon fiber strips sitting on a tube right behind it. This would allow me unroll the CF onto the mold with minimal handling.
http://losias.net/projects/osidias/p...s/p6050349.jpg
It was now time to mix up the resin. I was using a marine grade clear epoxy with a 109 medium hardener. This stuff has a pot life of about 30 minutes, so there was no time to do anything but get underway. With the resin mixed I was on the clock. I slipped on my rubber gloves and hit the mold with a layer of resin from a 4" lint-free roller. The first layer of CF was on soon after.
I continued wrapping and rolling, taking extra care not to deform or stretch the CF in any way. I also had to be sure that all the corners had the fiber nestled in them without issues. I thought I was making good time until I went to apply a little more resin, and the roller started to pull up on the CF. Crap! That meant my resin was hardening. Had it really been 30 minutes already? Well, it didn't matter. I couldn't do anymore at this point. I needed to wrap peel ply around it and get it bagged. I still had one layer to go, but there was no way I could get it on without causing serious issues. So, bag it, I did...
http://losias.net/projects/osidias/p...s/p6050350.jpg
I smoothed the bag out a little and left it under vacuum for about 2 hours.
http://losias.net/projects/osidias/p...s/p6050351.jpg
Now, aren't you all excited to see what's next? Yeah, I am too, but I had to head out of town for the rest of the weekend. The next update will likely be late Monday or Tuesday night.
So, overall, the experience wasn't as bad as I thought it might be, but I was cutting it close with the resin cure time. I also know I'll have a few ridges in the resin from the bagging process, but that's really not an issue right now. I can sand and add more resin. In addition, I'll likely go ahead and add the last layer of missing fiber. I'll update early this week guys!
I apologize for not updating last night guys. I've been struggling with a pinched nerve in my neck, and subsequent pain in my right arm. It was really bad yesterday, and I didn't even make it down to the shop. I'll be having an MRI done tomorrow, and likely have a surgery in my future. It sucks, but I'll keep plugging away. Despite being in a little pain, I'm gonna show you the CF. What you are looking at is the final layer of fiber needed on the case. I'll have to lightly sand a few small air bubbles, but otherwise it's cosmetically pretty darn good. I'm also going to apply one more layer of resin before I remove the mold. I want to be sure the CF is well protected from damage. It's a whole lot easier to sand and fix resin than have a blemish in the fiber itself...
http://losias.net/projects/osidias/p...s/p6080348.jpg
http://losias.net/projects/osidias/p...s/p6080349.jpg
http://losias.net/projects/osidias/p...s/p6080350.jpg
http://losias.net/projects/osidias/p...s/p6080351.jpg
They always say "No pain, No gain":D. Looks very neat so far. Cant wait for the next update
+1 good job man!!
Quote:
Originally Posted by D1RtY AssASS1n
Quote:
Originally Posted by josk1
Thanks guys! You know, I was just in the shop and I was hoping to get another layer of resin on the case. Unfortunately I forgot to shut the air conditioning vent last night, and it was too cool to cure as it should. Things will be fine by tomorrow, but I lost a day of work. I hate it when that happens... Anyway, to my point... It does look good I'll agree. I was just fondling it. Is that wrong? :D
Fondling is not wrong, sleeping with it may be questionable.
Licking it will make it better..... won't it?
Lol, I'll not lick it until there is at least one more layer of resin on it. You do not want one of those splinters in anything...
I'm enjoying watching this project progress a lot, sub'd :up: keep up the great work! Can't wait to see where this thing goes.
With the weekend come and gone, it's time I update all of you on my progress. It's not much, but as always, it's still a step forward. So, how about we get the case out of the mold? I designed the mold so that not only would it be reusable, it would be easy to remove. The first thing I did was to set the case on the workbench, and start tapping the core from one side to the other.
http://losias.net/projects/osidias/p...s/p6140348.jpg
http://losias.net/projects/osidias/p...s/p6140349.jpg
A few more taps...
http://losias.net/projects/osidias/p...s/p6140350.jpg
The core removed.
http://losias.net/projects/osidias/p...s/p6140351.jpg
Now it was a matter of removing the aluminum shell.
http://losias.net/projects/osidias/p...s/p6140352.jpg
It's finally free! The case is completely removed from the mold. You can see a few small voids on the interior, but those are a non-issue at this point. Anything that remains after the exterior holes are cut, will be filled in with resin and leave a smooth surface behind.
http://losias.net/projects/osidias/p...s/p6140353.jpg
http://losias.net/projects/osidias/p...s/p6140354.jpg
Now, I'll add a few comments about the case itself. It's strong! In fact, it's shockingly strong. Sure, everyone knows carbon fiber has excellent strength properties, but until you experience it for yourself, it's a little hard to quantify. This case has almost no flex or deflection. I can press on the center of both sides with about all the strength I can muster, and it just barely moves. It's just that solid. On top of it's strength, it's also incredibly light. Also, I'm saving the rest of the surface work until after all the holes are cut. This thing will be as smooth as glass once completed. All in all, this was the perfect building material for this case, and I can't wait to start making my first cuts in it. Stick around for the fun coming up next!
have always wanted to build myself a CF case... am really eagger to see what's next!!!
i got some CF parts on my motorcycle and i confirm: light and strong! no wonder they use it building formula 1 !!!
Thanks! I really like my experience with CF so far. It's initially a little more complex to work with than aluminum, but after you've got a solid piece, it's really quite easy to cut and file. I'm already going to change most of my interior parts over to CF. This will require some complex molding, but it should be great fun! So...Quote:
Originally Posted by josk1
Time for another update!
Now that the case is out of the mold, I need to get it cut down to size. I use my trusted tape marking method, and prep the Dremel. That's really the only practical way to cut the case with it's uneven contours.
http://losias.net/projects/osidias/p...p6140348-2.jpg
The first cut done. Would you believe that the CF cuts like butter with a reinforced disc? You can't drop the disc in and do a continuous cut without binding, but it you drop in every centimeter or so, it works very well.
http://losias.net/projects/osidias/p...p6140349-2.jpg
http://losias.net/projects/osidias/p...p6140350-2.jpg
Not only does the fiber cut extremely well, it takes to filing beautifully too. This pic was taken after filing and a quick bout with a fine grit sand paper. After cutting, I could finally get a measurement on the actual cross section of the case. It measures just under 2mm. That's even better than I thought.
http://losias.net/projects/osidias/p...p6140351-2.jpg
http://losias.net/projects/osidias/p...p6140352-2.jpg
With the first side done, it was time to mark the other side.
http://losias.net/projects/osidias/p...p6140353-2.jpg
All done! The case now measures the perfect 40.6cm I needed. Up next, I'll be marking out and cutting all the holes needed in the case. Until then!
http://losias.net/projects/osidias/p...p6140354-2.jpg
Interesting stuff with the Carbon Fiber, Craig :up:
Very nice,can't wait to see the outcome!
Thanks shazza!Quote:
Originally Posted by shazza
Thank you! I'm excited myself!Quote:
Originally Posted by Black Tears
Well guys, I've got some bad news, my quest for perfection is going to cause a delay in moving in with part of this project... I've decided I'm not happy with a few things. I don't feel the outer edges are 'sharp' enough. I think a side effect of the initial multiple layers of CF and the resin hardening too soon, have left things more rounded than I would like. The only way to fix this is to sand the case down, and add another layer of fiber. I can't just sand down what I have and resin because I'll have to sand through a little CF to get it flat. Obviously that will kill the cosmetics. While most of you think it looks great, it's just something that I've decided will bug me. I can't put countless hours into it, only to wish I had fixed it. So, what now? Well, luckily I still have work to do... I'll go ahead and start on the side panels. I've got to order more fiber, and the side panels will allow me to fill the time until it arrives.
i get what you mean by 'not sharp enough'... and we can see it on this photo:
http://losias.net/projects/osidias/p...p6140352-2.jpg
the ouside edges are roundish compared to the inside ones...
but does that really matter?
i'm not sur you could get a much better result.
you'd have to have thiner walls (less CF) otherwise you'll always end up with this result.
anyway, good luck with it!!!
The corners you see in the quoted pic aren't that bad. It's more of an issue with the corners on top of the case. Since there isn't much room between the two angles on each side, it's all together more rounded than I would prefer. The following pic best shows the issue...
http://losias.net/projects/osidias/p...s/p6140351.jpg
I've already sanded the case, and I think I'm going to get the results I want. I just need to get some more CF ordered now.
Although it's not quite as large an update as you all were expecting, I did manage to get a few things done over the weekend. A lot of people have questioned why I wanted to bother sanding down the case and adding another layer of fiber. Well, I've got a few pics that can hopefully show you in more detail why I wasn't happy. At this point, the case is sanded and ready for it's last layer of CF. It's nowhere as pretty as it was before the sanding, but that will be remedied soon. Trust me... :D
http://losias.net/projects/osidias/p...s/p6190351.jpg
Now, here is the best way I can show you the before and after examples of the 'rounded' edges I was speaking of. This should make things pretty clear. This is a before pic, taken of the excess I cut off of one of the ends...
http://losias.net/projects/osidias/p...s/p6190353.jpg
Now take a look at the after. You can see there is no more rounded edge, and I'm much happier.
http://losias.net/projects/osidias/p...s/p6190352.jpg
Okay, now with that out of the way, it's time to move on to the side panels. I'll be working on them until I have more regular CF arrive to finish the case itself. As you are about to see, making the molds for these panels is a whole lot easier than before. Two bends and I was golden. This nice piece of aluminum will be the basis of what is to come.
http://losias.net/projects/osidias/p...s/p6190354.jpg
A few bends later...
http://losias.net/projects/osidias/p...s/p6200355.jpg
Now I've just got to get the CF/Kevlar blend cut to size, and I can get the fiber laid down. Hopefully tomorrow!
http://losias.net/projects/osidias/p...s/p6200356.jpg
Well, I've got a little more work done on the side panels. I'm using the same molding process as the case, but it's nowhere near as complex this time around. Here is the Kevlar/carbon fiber blend laid out and ready for marking... Isn't it pretty?
http://losias.net/projects/osidias/p...s/p6220348.jpg
I've marked out the fiber, and am making my cuts here. This stuff truly sucks to cut. Even with a specialty shears, it has a tendency fray and not cut cleanly. I wouldn't ever attempt this with regular scissors. I would imagine you would slit your wrists in frustration.
http://losias.net/projects/osidias/p...s/p6220350.jpg
Now finally, here are 5 layers of fabric freshly removed from the vacuum bag. I've still got plastic peel ply on it, but that will come off tomorrow. I'm going to sand a little, and add one more layer of Kevlar. The same procedure I used on the rest of the case, should get me pretty good results. The trick will be in finding the perfect piece of fiber for the top layer. The weave on this blend is very sensitive, much more so than with regular carbon fiber. Every little flaw or misalignment seems magnified 10 fold. I'll manage though... or go insane trying!
http://losias.net/projects/osidias/p...s/p6230351.jpg
Tomorrow I'll get the other panel started, and sand this first one. Then I've got to get an end mill or two ordered for the Romaxx CNC. I'll be using it to cut out the side panels. I'll do a few test runs first, since I don't want to screw one of these up. Mistakes would be costly...
If it weren't for pictures like the following, I'd take the Kevlar/CF blend, and make it disappear... Yes, it's a royal pain to work with. I knew it would be, but until you are actually working with it and trying to make it do what you want, you have no idea...
http://losias.net/projects/osidias/p...s/p6250349.jpg
http://losias.net/projects/osidias/p...s/p6250348.jpg
http://losias.net/projects/osidias/p...s/p6250350.jpg
It doesn't like to cut cleanly, no matter the process. The Kevlar fibers really have a mind of their own. I've found that I get the best results if I start cutting with a metal carbide cutting wheel. That cuts quickly, but not cleanly. I then followup with a reinforced cutting disk. This cuts much more cleanly, but it's slow. I can't take much material off with each pass. After that, I use a file to straighten the cuts. Then finally, I finish up with a 320 grit wet/dry sand paper. This does a decent job of cleaning the edge up, but it takes a light touch. So, that's one heck of a process for a single cut!
Time to cut! I used a yardstick as a straight edge, and followed up with my line taping method.
http://losias.net/projects/osidias/p...s/p6250351.jpg
An hour later I had two sides done... This is gonna take a while. Lol.
http://losias.net/projects/osidias/p...s/p6260352.jpg
so amazing. Great work at the carbon fibre ;) love your build and want to see more pictures :D
This truly is amazing work, both in design and execution. I read your build log for the Rogue some time ago and thought that was simply astonishing but this is taking modding to the next level.
I think I've read somewhere that electric power scissors like these work wonders for cutting the carbon fiber fabric, maybe something similar might be worth a try. I also hope you use a proper respirator when cutting the finished panels, the dust from the fibers and resin is pretty nasty stuff.
Thanks ipuoL! I'll have more updates this week!Quote:
Originally Posted by ipuoL
Thanks maped! I find that with each build I have to take things a little bit farther than the one before. It's a little scary to think about what might be in the next one!Quote:
Originally Posted by maped
Someone on another forum suggested similar power scissors. I'm not sure if I'll just stick it out with what I have, or try something new. The regular CF fiber cuts really well. It's just the Kevlar blend that's a pain. I do use a proper respirator. That dust is fine, and gets everywhere!
Amazing dude....totally love it :up:
Thanks mate!Quote:
Originally Posted by miahallen
Okay guys, I had to make a little time for something unrelated to carbon fiber. It also has nothing to do with actual modding. What follows is just an example of why I've said that the planning for the case is only about 95% finished. Little things like this are always changing and being added. I live for the little details that some take for granted.
So, what we have here is an integrated heatsink for the water pump. It also doubles as a vibration proof mount for the pump via grommets. Once in place, air from the radiator fans will help with the cooling.
http://losias.net/projects/osidias/p...v1-4-pump1.jpg
http://losias.net/projects/osidias/p...v1-4-pump2.jpg
http://losias.net/projects/osidias/p...v1-4-pump3.jpg
http://losias.net/projects/osidias/p...v1-4-pump4.jpg
http://losias.net/projects/osidias/p...v1-4-pump5.jpg
http://losias.net/projects/osidias/p...v1-4-pump6.jpg
This heatsink will make it's way to my CNC machine in the future. You can also see that I've changed the interior parts over to carbon fiber. Creative mold making will be coming!
For anyone that has been following the project details closely, you'll have noticed I've got quite a few holes that need to be cut in the exterior of the case. Since I tend to try for perfect execution, I needed a very reliable and accurate method of marking those holes out on the case. I used the following method on the Rogue with great success, and will continue it here.
This is a transparent adhesive sheet used for printing labels. It's simply a matter of printing out the guidelines, which is made even easier since the entire project was designed in CAD. If you look closely, you can see an additional guideline extending to the left and right on the lower part of the design. This will help in placement.
http://losias.net/projects/osidias/p...p6150349_0.jpg
Next was the matter of proper alignment on the case. While it's pretty easy to place the sheet, I triple checked the measurements since they had to be perfect.
http://losias.net/projects/osidias/p...p6150350_0.jpg
With the adhesive label in place, it was time to add my masking tape guide lines.
http://losias.net/projects/osidias/p...s/p7120356.jpg
Time to break out the Dremel! I had to take it slow and steady here. You can't exactly fix any miscuts or slips... Even so, I managed to make quick work of the carbon fiber, and was soon left with a rough cut.
http://losias.net/projects/osidias/p...s/p7120357.jpg
After some filing, and sanding, I was left with the finished hole! My patience paid off, and I was left with a hole that was visually perfect to me. Now I've only got about 6 more to go.
http://losias.net/projects/osidias/p...s/p7120358.jpg
Ahahah good luck Craig with the other 6 :)
Thanks mate! I'll see if I can get a few more done tonight.
Look's amazing bro i'm looking forward to see more from this project's :shocked:
wow mate, like where this is heading.. U have some serious skills!
Thanks as always man!Quote:
Originally Posted by Soul_train
Thanks Johnny, I appreciate the compliment!Quote:
Originally Posted by Johnny87au
I did stream live last night guys. How's that for brave? If I screwed up, I couldn't hide it. :D The 3 newest video's were recorded July 14th and 15th. You can see me cutting the holes out in the carbon fiber. There were only a couple times I had any real binding with the Dremel disk, but a firm grip helps keep things under control.
http://www.livestream.com/losiastechnologies
I've only got a few pics here, as the process for each hole doesn't change. Mark, cut, sand. It's progress though!
In this pic I had already cut the second hole in the case. You can see video of that on the livestream link above. I've also got the hole marked out for the Aquaero.
http://losias.net/projects/osidias/p...s/p7150354.jpg
After cutting, I was left with another pair of holes. Now only 4 more to go!
http://losias.net/projects/osidias/p...s/p7150355.jpg
http://losias.net/projects/osidias/p...s/p7150356.jpg
and i thought my desk'built was a pain in the a$$... ;)
Haha, this isn't bad so far. Honestly, the worst part will be the wiring. I'll be using touch contacts, and the entire interior of the case will slide out the back.Quote:
Originally Posted by josk1
I just had a look at your desk build. That's pretty impressive!
Love the way you build it up man :up:
good luck with the build....
Thanks, I appreciate it SnW!Quote:
Originally Posted by SnW
Well guys, I made a few more holes tonight. I was also streaming live again, so be sure to check out the Livestream for the newest videos. (Be sure your volume is turned down a little, as the mic seems to be working a little too well...)
So, let's get this started! Here you can see the freshly cut hole for trio of 60mm fans that will sit over the video cards. This makes for 4 holes done, only 3 to go!
http://losias.net/projects/osidias/p...p7150354-2.jpg
http://losias.net/projects/osidias/p...p7150355-2.jpg
At this point I decided to clear up a question or two regarding this case's strength. I was trying to think of a good way to convey how strong the carbon fiber really is. You can see with the holes cut out, there really isn't a large amount of supporting material left in the lower part of the case. Well, I'm telling you that it doesn't matter in the least. Here you can see my daughters full 103 pounds being supported by the case. There's nary a flex! I can guarantee that aluminum would not have fared so well...
http://losias.net/projects/osidias/p...p7150356-2.jpg
With the case still in one piece, it was time to get back to cutting. For those that were following the planning thread, you'll remember that the windows on the side panels will actually be transparent LCD's. In order to get them to fit correctly, I've got to get a hole put in each side of the case for the circuit board. Here I've got the hole all marked out.
http://losias.net/projects/osidias/p...s/p7150357.jpg
The rough cut done!
http://losias.net/projects/osidias/p...s/p7150358.jpg
I'll have more in the coming days, so until then!
nice work dude, keep em coming!!
Thanks bro. I'll have another update Monday night or so.Quote:
Originally Posted by Johnny87au
Carbon fiber aside... "WHO DAT?!"Quote:
Originally Posted by craigbru
Lol, that's my daughter dude. She's only 14, so don't get any bright ideas. :DQuote:
Originally Posted by ScottALot
Ideas like that aren't usually that bright :rofl:.Quote:
Originally Posted by craigbru
But that's one seriously strong case Craig :eek:
Agree dude, Carbon fibre is generally strong, Can hold its own weight x10Quote:
Originally Posted by Alexandr0s
Lol, that's so true.Quote:
Originally Posted by Alexandr0s
But yeah, it's beyond strong.
I didn't have a scale, but I found the only thing comparable in weight. It weighs as much as a banana... An large banana weighs about 7 ounces. So, it's holding roughly 235 times it's own weight. Isn't math fun? :DQuote:
Originally Posted by Johnny87au
Okay guys, I'm looking to live stream some work tonight. It will most likely be between 8~11pm central standard time. You can catch the stream at either of the following two links. One is on my site, the other is on the Livestream site. Either will be the same, and commenting during the stream is easy, although I won't likely respond to much until I'm done working.
http://losias.net/losias-live/
http://www.livestream.com/losiastechnologies
Since I do things on the fly, I usually record in segments. It keeps the filler and wasted screen time to a minimum. Also, no one really wants to sit down and watch a 2 hour video. I try to keep most under 30 minutes.
So, you can feel free to check either link at your convenience. Also, one of the easiest ways to see when I'm streaming is to follow my twitter feed. It's @craigbru'. I usually send a message when I'm about to go live.
Tonight I plan on finishing up the rest of my case holes!
I've never seen anyone do this before (correct me if i'm wrong, i might just be slow :p:), awesome idea :up:Quote:
Originally Posted by craigbru
I know there are others that record video and later edit it, but I don't know of anyone streaming live. If there are, I haven't come across it yet. I stream for a couple of different reasons. People get to see actual work being done that can't be explained in simple pictures. In pics you get points A, B, and C, but you don't get to see how I got to each of those points. Also, as much as I do love a good video worklog, I simply don't have the time to edit and post a lot of videos. I'd rather spend that time modding. :DQuote:
Originally Posted by jordan-com
Sounds great Craig!
I'll be tuning in. :)
This made my day.Quote:
Originally Posted by ScottALot
Incredible Thread! Looking forward to the final build.
Also you mind providing us with a overview of how the wireless control system would work?
Sounds great Charles! I'm not sure how exciting it will be, but we'll give it a go. I've got to do some filing on a previous hole, and then I'll get in with cutting new ones.Quote:
Originally Posted by charles_h
Lol.Quote:
Originally Posted by Cookiesowns
Thanks man. I'd be happy to give you an overview when I get a chance. Give me a day or two though. I'm headed to the shop in about an hour and have a few things to finish up first.Quote:
Originally Posted by Cookiesowns
Are there not going to be any more pictures in this thread or will there be videos and pictures ? I prefer pictures personally.
What would you have done if the demonstration had failed and it had broken ? :o
Quote:
Originally Posted by yngndrw
There will be more pictures, but I didn't get any tonight. The video is supposed to supplement the images. I got about 2 hours worth of streaming in tonight. I did manage to get the other hole for the LCD circuit board done, as well as the hole in the top of the case. I've got one more hole to put in the left side for the PSU, and then a small hole in the bottom of the case for ventilation on the pico-itx board that will be located there.
If the stream had failed, then I would have just taken pics as usual. Ironically, my host DNS went down as I was streaming, and the video was only viewable in the Livestream website.
http://livestre.am/glpt
http://livestre.am/gl6b
http://livestre.am/gkTY
c'mon craig your leaving us hanging :)
Lol, I'll get a few real pics of the work I did last night, as well as a regular forum post to explain what I've done. I'll try not to keep you guys hanging for long. ;)
Wow its so strong keep it up Craig :up:
Thanks! Yes, it's definitely strong. Even with all the holes in the case now, it doesn't seem much weaker than before. While I once thought it was a bit of overkill, I now realize this could have never worked as aluminum. Carbon fiber was really the right choice.
I had a few minutes...Quote:
Originally Posted by Cookiesowns
Okay, here's a brief overview of the wireless networking and monitoring setup. It's sometimes a little hard to wrap your head around, but I'll try and give a clear explanation.
I've basically got 3 complete computer systems in this case. I've got the main system consisting of the Asus matx board and associated components. Then I've got a Via pico-itx system acting as an always-on file server, and information monitor. Finally, I've got the Viliv UMPC that sits on the front of the case. These 3 systems are connected by both an internal ethernet hub, and an Asus wireless access point. The wireless network is used for information sharing and control by the Viliv. The Viliv is obviously a wireless only connection, but the other systems can connect either wired or wireless, and be independent of any other system.
Since the pico is always on, it serves to relay most of the system information. It will be attached to an Aquaero and Multiswitch, which in turn is responsible for all watercooling, temp sensors, and lighting. It will also allow me to turn the main system on and off through the Viliv. All the information I need on the Viliv will be relayed using a Samurize front end. Samurize's own network monitoring functionality, as well as the Aquaero software will allow for real time monitoring of the pico and main system functions. Now, of course since the Viliv is wireless, and always connected to the OSIDIAS network, I can just detach it from the case and use it as a remote.
Does that help? Feel free to ask if it doesn't.
I think it would be awesome for you to stream you setting it up and when you get to it, running it all together with some commentary along the way just explaining what it's doing, how it works, etc.Quote:
Originally Posted by craigbru
I just found this thread and I'm kind of glad, since it appears to be well over a year under development (my selfish reason :p:) but it's awesome man! I'll be checking out your streamed videos when I get home later. I wish I saw this thread *before* I went home for lunch and watched some other garbage on livestream :rofl:
Keep up the great work!
I'm not sure anyone would want to watch the setup of that. There's bound to be quite a few WTF moments as I try to get it all sorted. ;) I'll sure make a video of everything working once it's completed though.Quote:
Originally Posted by Rise
Yes, it was over a year in planning, and in fact, I'm still making a few small changes as I go along. That's the fun part though!
Dude, I freaking love the videos :D.
Regarding the remote control system - Is there a specific practical use for it that you have in mind or is it just being done because it's cool and because you can ? (Sorry if you've already answered that and I missed it, but I didn't see it when I just looked.)
Thanks bro!Quote:
Originally Posted by Alexandr0s
It's actually a little bit of both. I'm really big on monitoring all the minute details of my system. The remote screen allows me to do that from either the front of my PC, or anywhere else in my house. It's maybe a bit of overkill, but the Viliv is a great device in it's own right. I use it for watching videos, and keeping up on the forums quite a bit. It's usually next to me when I'm watching TV at night for example. With it tied into the system like it is, it makes it pretty easy to check download status on files and monitor other functions while away from the PC. I could remove it when benchmarking so I don't need to be in front of the PC, and still monitor vitals. Anyway, those are just a few of the ways I justify it... :DQuote:
Originally Posted by yngndrw
Ah I see.
When you have something as cool as your design, you don't need to justify anything. ;)Quote:
Originally Posted by craigbru
Personally i prefer people like Craig with such fine skills, dedication and uncompromising standards being paid millions than the CEO's of wall street. :clap:
then again maybe he is ;P
Lol, well, sometimes I need to justify things to myself. Especially when they are pricey additions. Luckily I'm a sucker for my own reasoning.Quote:
Originally Posted by yngndrw
Thanks mate. I would certainly be all for that. I'd definitely go nuts without a budget to think about. Actually, that's a little scary...Quote:
Originally Posted by bladechai
Dude, I so wish. :D
Meh, anyone can get awesome stuff with a budget like that. It takes true skill to make something awesome like what you're building without a very big budget :D.Quote:
Originally Posted by craigbru
True, money is nothing without imagination. It's not about the latest and greatest hardware, it's about trying to do something original with whatever resources you do have. :up:Quote:
Originally Posted by Alexandr0s
Yay, DIY ftw! Why buy a case when you can build one, more awesome than what ever will be sold in stores?
I've been lucky enough to see both sides of this hobby. I've been doing case mods for years now, and always thought it would be cool to make something that was actually marketable. Well, I did get that chance last year. I worked with Johnny Hou of NZXT on their upcoming Phantom case. The interior design and layout were what I focused on, as the exterior is all Johnny... It's amazing how many compromises sometimes have to be made for cost and feasibility reasons. Every dollar adds up, and some features I wanted had to be changed or dropped. When you are doing your own work, you never have to think about things like that. :DQuote:
Originally Posted by Alexandr0s
Thanks to inspiration from Javi, dbradford, and w33dy at the Mod Brothers forums, I've done a little something to help with my dust collection. I really needed a third hand when cutting on the workbench, and with none in sight, I came up with a great alternative. I modded an old architect lamp!
I couple of velcro straps, and the vac hose was attached to end of the arm. After using it for a few cuts, I've got to say that it's quite effective for a low tech solution. I'm guessing it's catching at least 75% of the dust caused by cutting.
http://losias.net/projects/osidias/p...s/p7270355.jpg
http://losias.net/projects/osidias/p...s/p7270354.jpg
So, with a decent dust collection solution in place, it was time to put it to use. I was streaming live during a portion of this, so I'm missing a few pics. With most of the side holes done, it was time to move to the top. Here is what it looked like after cutting.
http://losias.net/projects/osidias/p...s/p7270356.jpg
http://losias.net/projects/osidias/p...s/p7270357.jpg
Now it's time to move back the side. The last hole I need to cut is where the PSU will sit. Here is the hole all marked out. (Live Stream)
http://losias.net/projects/osidias/p...s/p7270358.jpg
All cut! (Live Stream)
http://losias.net/projects/osidias/p...s/p7270359.jpg
And finally a test fit with a PSU in place.
http://losias.net/projects/osidias/p...s/p7270360.jpg
Dude this case is mint, love the carbon fibre feel!
all those holes... wow! ;)
Thanks Johnny! I can't wait until I can sand this thing a little and get the final coat of resin on it. I'm going to make it look like glass!Quote:
Originally Posted by Johnny87au
Lol, yes, there are quite a few. The CF is still really strong though. Aluminum would never have survived. It also likely would have bent out of shape with all the abuse I've thrown it during cutting. There's no bending here though! :DQuote:
Originally Posted by josk1
Cant wait dude, cant wait ;)Quote:
Originally Posted by craigbru
Amazing Work Man. this Case is looking like a Million Bucks so far, Cant wait for final pics.
Lol. I hope you're a patient guy. We're talking months before completion yet. ;)Quote:
Originally Posted by Johnny87au
Thanks man! It's not even to what I would call a 'pretty' stage yet. :DQuote:
Originally Posted by C-J
For your dust extractor, you could try mounting it to your Dremel - If you made a clear plastic dust hood to go around the cutting disk you could connect more dust and still see where you're cutting. Additionally you can cut anywhere without having to move the cut under the vacuum hose.
The shape would be like this blade guard:
http://www.thetoolcounter.com/acatalog/GSA25.jpg
Lol. I hope you're a patient guy. We're talking months before completion yet. ;)
No problem, I can wait....:up:
While that may work, I'm guessing that it might make the Dremel a little hard to control. That's something I'm pretty sensitive about. I've got to have absolute control. ;)Quote:
Originally Posted by yngndrw
That's a good thing, lol. There are some things yet to come that are going to take some thinking to implement. I'm currently working on making an aluminum mold for the interior tray. It's going to be solid CF, and the mold is a puzzler...Quote:
Originally Posted by bladechai
Update time! Today we pick up with the start of the interior assembly. Since I'm a glutton for punishment, I've decided to make the entire thing out of a single piece of molded carbon fiber. Since the dimensions have to be perfect, I am going to be using a two part mold. An inner and outer layer, with the CF sandwiched in between. In order to pull this off, I've got to do some very careful measurements, and even better cutting.
I'll be using 1.5mm aluminum for the molds. Here you can see a 4' piece marked down the center. I should be able to get both an inner and outer mold out of this 2'x4' sheet.
http://losias.net/projects/osidias/p...s/p7290354.jpg
Next up I've got to mark out all my cut and bend lines. There is no room for error here. Everything is down to the millimeter.
http://losias.net/projects/osidias/p...s/p8050355.jpg
After the rough cuts were made...
http://losias.net/projects/osidias/p...s/p8060356.jpg
After spending a maddening long time with the aluminum in my metal brake, I was left with the following. Mind you this was a little tricky, since it didn't exactly fit in there very well after the first few bends...
http://losias.net/projects/osidias/p...s/p8060357.jpg
http://losias.net/projects/osidias/p...s/p8060358.jpg
Now it was time to stick it inside the case for a test fit. I had no doubt everything would line up, but it's always a good idea to double check.
http://losias.net/projects/osidias/p...s/p8060359.jpg
http://losias.net/projects/osidias/p...s/p8060361.jpg
Next up is the outer mold. Once that is completed, I'll rub down the aluminum with release wax, and play with a little more carbon fiber. Woohoo!
Also, as of this morning, I've learned that OSIDIAS was nominated for bit-tech mod of the month! I'm honored!
http://www.bit-tech.net/modding/mod-...th-july-2010/1
Congrats on your nomination!! Its always nice to be noticed.
Thanks for the update. This build has been one of my favorites by far.
If you don't win then whoever decided needs their eyes checking.
Sub'd for epic SFF.
looking good, hope to see updated sooner "hint hint" :D
Thank you! It definitely does feel good. There's always some great competition as well.Quote:
Originally Posted by OC Maximus
Lol, I'm doing pretty good in the polls so far. Funny thing is, when I saw I was nominated, I was a little surprised. I didn't think I had nearly enough work done to justify it.Quote:
Originally Posted by yngndrw
Thanks man!Quote:
Originally Posted by UrbanSmooth
Thanks bro! I probably won't have an update until later this week. I've got to get some work done on another project with a new deadline.Quote:
Originally Posted by Johnny87au
Keep it coming bro :D
looks amazing and great work you have done in that cut's :up:
Honestly, has to be one of the top 10 builds of 2010. Keep it coming Craig, keep it coming.
Thanks! I always appreciate the compliments from you Soul. :DQuote:
Originally Posted by Soul_train
Thanks bro! I aim to please!Quote:
Originally Posted by OC Maximus
Although Project Hutch has been getting most of my time lately, I was able to get a little work done on OSIDIAS while waiting for some JB Weld to dry... I picked up on the continuation of the molds for the interior assembly. When I last updated, I had the inner mold completed. Now it was a matter of laying out and cutting the exterior. What you see here is another 1'x4' piece of aluminum sheet.
http://losias.net/projects/osidias/p...s/p8170364.jpg
After cutting...
http://losias.net/projects/osidias/p...s/p8170365.jpg
Time to get this thing bent!
http://losias.net/projects/osidias/p...s/p8170366.jpg
http://losias.net/projects/osidias/p...s/p8170367.jpg
http://losias.net/projects/osidias/p...s/p8170368.jpg
http://losias.net/projects/osidias/p...s/p8170369.jpg
http://losias.net/projects/osidias/p...s/p8170370.jpg
Now, to get one of the inside bends done, I had to switch to my 18" brake.
http://losias.net/projects/osidias/p...s/p8170371.jpg
With all of the bends done, it was time to see how they fit together. I slipped the outer mold over the inner, and all was well! I've got about 2mm between them. That should allow for about 6 layers of carbon fiber.
http://losias.net/projects/osidias/p...s/p8170372.jpg
Since I knew the molds were going to work, it was time to reinforce the inner mold against flexing. All I needed was a piece of 2x4 cut down to 8cm in width. The board was aligned and epoxied in place. Final measurements indicate that I got the perfect alignment I was hoping for. The back is perfectly parallel top and bottom, and I won't need to make adjustments of any kind.
http://losias.net/projects/osidias/p...s/p8170373.jpg
Up next I've got to add a few pieces of angled aluminum for mounting tabs, and I'm ready to wax and lay down the fiber!
Nice bends Craig! :)
How many brakes do you have?!:) Is that 18" useful or do you use big one more often?
Thanks Mike! I've got two brakes. A 40" and the 18". The big one is much easier to use, but I have clearance issues on some parts. The smaller will fit almost anything, but it sometimes flexes and lacks enough leverage for thicker materials.Quote:
Originally Posted by phinix_mike
looking good pal, havent been back in a while lucky u havent updated it to much hehe!
Thanks bro! I'll have a hopefully epic update soon. I think I'm mostly prepped for tomorrow. I just have to cut the layers of CF down to size in the morning. I've been running the process through my head. I've got less than 30 minutes to wrap 6 layers around and get the outer mold in place. Realistically I'd like to get it done in 20. That would leave me with time to spare in case adjustments are needed. If the outer layer weren't cosmetic, it wouldn't be so bad, but it has to be perfect. Lol, I'm stressing a little. I do have the molds all waxed and ready to go. I've also waxed and layered a small patch of fiber down on a test piece of aluminum tonight. I want to be sure it releases correctly. If not, that would be messy...Quote:
Originally Posted by Johnny87au
you could save much more space if you use a picoPSU
I'd save tons of space... but there wouldn't be nearly enough power. The mains system is high end, and the case is packed with other goodies requiring lots of power. :DQuote:
Originally Posted by nn_step
your tower looks like this ... to this i say good job
http://software-be-we.com/images/cx1_photo.jpg
Excellent work so far....I'm loving this build :up:
Speaking of which, I haven't seen a parts list....what HW are you going to use? :shrug:Quote:
Originally Posted by craigbru
Nice! I hadn't seen that before, but now that you put that pic up, I can definitely see the similarities. Part of my original inspiration came from a RED camera cage I saw quite some time ago.Quote:
Originally Posted by Sn0wm@n
Thanks! I'm going to use my existing hardware for the moment. Granted, by the time this thing is running, I'll be looking to upgrade again. Right now I've got a Silverstone Decathlon 1000 watt PSU, Asus Rampage II GENE, i7 920, OCZ ram, a pair of Saphire Vapor-X 5870's, OCZ SSD's, and a slot load Blu-ray drive. I've also got MIPS, and Heatkiller 3.0 blocks for the board. Then I've got the side LCD screens, the Viliv, two radiators, pump, the Aqua Computer Aquaero, multiswitch, and flow meter, LED strip lighting, Silverstone hot swap SATA connectors, the Via pico-itx (with it's own SSD), Asus wireless access point, 5 port ethernet hub, Bitspower compression fittings, and a Koolance reservoir... That covers most of what I can remember. Lol.Quote:
Originally Posted by miahallen
Update time! I actually livestreamed the fiber going down, although it was a huge pain. For some reason I thought it was a good idea to skip taping the edges of the fiber. Needless to say those stray fibers soon became a problem as the layers went down. I managed to keep them out of the way, and got 5 layers on before I ran out of resin. That means I'm a layer short of what I wanted to be. Although looking at the finished assembly, it's likely thick enough, but I'm going to give it one more anyway. I had a little trouble sliding the outer mold in place. The resin kept sticking to the mold and pulling it down with it. Doh, why didn't I wrap plastic around it before the mold?! That would have taken care of the problem, and I'd be done. As it is, now I've got to sand and add the last layer anyway. Mostly for cosmetic reasons mind you. The outer mold caused some wavy weaves because of the sticky resin... and I just can't have that. I'm out of resin though, and will have to order more before continuing.
Well, enough of that. On to the pics! Here I'm using a template to cut out the layers of CF.
http://losias.net/projects/osidias/p...s/p8280365.jpg
Obviously I couldn't take pics while wrapping, but here is the mold all clamped up.
http://losias.net/projects/osidias/p...s/p8280366.jpg
Now it was time to see if that mold wax release was going to do it's job. I had a total of 3 layers on, so I was pretty confident. Success! The outer mold released without an issue. Here you can see the interior assembly in it's freshly released state. There are a few spots that didn't get completely 'covered' with resin, but it's hardly an issue. There was complete saturation and it's damn solid!
http://losias.net/projects/osidias/p...s/p8280367.jpg
Finally, I took the dremel and cut off most of the excess fiber. You can see the interior mold is still in place. There's a good reason for that. It is cut to the exact dimensions that the assembly needs to be. During the final cut down, I'll use the interior mold as a guide to make sure everything is cut correctly. Without it, I don't think measuring out where I needed to cut would have been so fun...
http://losias.net/projects/osidias/p...s/p8280369.jpg
http://losias.net/projects/osidias/p...s/p8280370.jpg
At this point I've got to get some more resin ordered. In the meantime I'll sand down and prep the interior for the last layer of CF. Then I can start making holes in it for all the components and wiring. Woohoo!