Daniel's murderbox - with a sLight twist

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01-10-2009, 01:00 PM
breathemetal

Very nice Charles!
01-10-2009, 05:11 PM
Henry8601

Wow - yet more amazing bits of work Charles. It's always great seeing the next thing that you come up with!
01-10-2009, 06:40 PM
hiiyah777

Hey Charles, not to be too off-topic here, but just letting you know that I've FINALLY posted my work log today. Have a look if you'd like:

http://www.overclock.net/case-mod-wo...d-worklog.html

And keep the updates here coming, I check three times a day for updates. (Does that make me an addict? Surely not!)
01-11-2009, 11:32 PM
charles_h

Cheers Guys! :)

Hiiyah: Awesome! I’m really looking forward to following your build!

Project Update:

I will now destroy this innocent piece of Aluminum (sensitive viewers may want to avert their eyes).

http://www.murderbox.com/uploads/DS.mM.026.jpg

The Aluminum plate that will be used to fabricate PLED structural mount.

The first step is to prepare the internal plate by removing the angled edge – it’s not needed.

Cylindrical Aluminum standoffs will be used to mount the internal plate to the existing TJ07 vertical structure.

http://www.murderbox.com/uploads/DS.mM.027.jpg

Since the closest length is 1” and they’ll need to be shorter, they’ll have to be filed down a bit – more on that later.

We’ll start by cutting the angled edge off the plate with a jigsaw. I’ll secure the plate and freehand cut this sucker.

http://www.murderbox.com/uploads/DS.mM.028.jpg

Sometimes I’ll use a cutting guide but this cut is pretty simple – I’ll take my time so as to avoid a Freudian slip. ;)

http://www.murderbox.com/uploads/DS.mM.029.jpg

Oh no; he didn't just say that...

Ok, enough foolishness... time to get down to business.

http://www.murderbox.com/uploads/DS.mM.030.jpg

http://www.murderbox.com/uploads/DS.mM.031.jpg

Once the cut is done, I’ll clean up the edge with a bastard file and Emory cloth.

The next step is to build a template for the PLED mount holes. For this I’ll use a piece of clear Plexiglas.

http://www.murderbox.com/uploads/DS.mM.032.jpg

I carefully measured the PLED mount holes and created an accurate paper template which I then transferred to the Plexiglas. The next step is to overlay the template onto the plate and lineup the grid with the opening.

http://www.murderbox.com/uploads/DS.mM.033.jpg

Once the plate is marked and triple checked, I’ll drill the PLED mounting holes. No need to show drilling shots – I’m sure you guys know what that looks like.

http://www.murderbox.com/uploads/DS.mM.034.jpg

Since we’re short on available space yet want to use a clean front facade, I’ll oversize the display openings in the internal plate. This will provide the clearance needed by allowing us to countersink the top black portion of the PLED flush with the outer edge of the internal plate - thus gaining the critical 1.5mm needed.

http://www.murderbox.com/uploads/DS.mM.035.jpg

Confusing? I show.

I’ll start by setting up the plate and preparing it for the operation.

http://www.murderbox.com/uploads/DS.mM.036.jpg

Next, I’ll grab my trusty Dremel…

http://www.murderbox.com/uploads/DS.mM.037.jpg

I’ll use the wood as a guide and carefully…

http://www.murderbox.com/uploads/DS.mM.038.jpg

Wait a minute!

Mr. Dremel, you are too puny…

This task calls for pure spinning destruction... the kind that only the RotoZip can provide.

http://www.murderbox.com/uploads/DS.mM.039.jpg

Oh hell’s yeah.

Now that I'm using the RZoD, I really need to make sure the cutting guide is accurate. With the right bit, a RotoZip is pure destructive pleasure but you cannot freehand cut a straight line - unless you're a brain surgeon maybe!

http://www.murderbox.com/uploads/DS.mM.040.jpg

Now we're ready!

http://www.murderbox.com/uploads/DS.mM.041.jpg

http://www.murderbox.com/uploads/DS.mM.043.jpg

Sorry, no live action shots - I can't RotoZip with one hand (well, I probably could but I don't want to end up with one hand!).

http://www.murderbox.com/uploads/DS.mM.044.jpg

One line down, 11 to go…

http://www.murderbox.com/uploads/DS.mM.045.jpg

The first one is done.

http://www.murderbox.com/uploads/DS.mM.046.jpg

All done!

Ok, time for a cigarette (even though I don’t smoke). I’m a simple man of simple pleasures; using the RotoZip is one of them. The one downside is of course the cleanup. While mostly contained, I do find frags as far as 10 feet away.

http://www.murderbox.com/uploads/DS.mM.047.jpg

ShopVac... front and center - Stat!

Next, I’ll countersink the mount holes and test fit the PLED using temp bolts.

http://www.murderbox.com/uploads/DS.mM.048.jpg

I’ll use rubber grommets as spacers for now, these will likely be swapped for nylon spacers later.

http://www.murderbox.com/uploads/DS.mM.049.jpg

http://www.murderbox.com/uploads/DS.mM.050.jpg

That’ll work!

http://www.murderbox.com/uploads/DS.mM.051.jpg

Finally, I’ll lay the facade in place to get an idea of final look.

http://www.murderbox.com/uploads/DS.mM.052.jpg

Well, that’s all for today. The next step is to mount the internal PLED plate to the existing vertical structure and attach the facade. This should complete the mockup and fabrication of the PLED mount - then I can get the measurements needed for the side panel water jet cutting. The next phase will be to design and construct the lower section of the LC loop and then it’s off to powder coating. Somewhere in there lies the new concept that I’m super excited to reveal!

Until then - thanks for looking in. :)
01-12-2009, 12:32 AM
IcEWoLF

Very nice charles, that looks amazing!
01-12-2009, 12:34 AM
Yil

Hi Charles,

when will they be available in the Murdermod shop??

Gr Yil
01-12-2009, 12:42 AM
ultimeus

Nice update Charles, I see murderbox signature on this too ;)
01-12-2009, 01:09 AM
dingdong555

Charles my friend, you're work is beyond outstanding. I'd kill to see what you can do to case in 10years ;)

Perfectionist......that you are spedo man!
01-12-2009, 04:08 AM
hiiyah777

Looking brilliant as always, Charles!!!
01-12-2009, 06:02 AM
moogle

Quote:

Originally Posted by charles_h

bastard file

:D

Nice to see more great work by you charles :up:
01-12-2009, 06:15 AM
dsecrieru

I love big updates! :D

Awesome display of your skills and tools man. It's all coming together quite nicely. I can even see the Light at the end of the... tunnel, yes tunnel. ;)

Daniel.

P.S. I hope your health's better and the flu is gone.
01-12-2009, 12:19 PM
Dangals

Charles you are a wonder - you make everything look so incredibly simple and on top of that you make it easy (and enjoyable) for everyone to follow. :clap:

My hat of to you sir :yepp:
01-12-2009, 12:48 PM
SNiiPE_DoGG

Charles I take it you have your waterjet machine recently setup so there is very little damage to the slats on the bed, or do you use a protection coating? the one I have to work with here at school is very torn up and it rips the finish on the panel up.
01-12-2009, 03:35 PM
theseeker

Charles,

In addition to your other many talents, it is apparent that you are jigmeister too! Beautiful work my friend!
01-12-2009, 04:41 PM
charles_h

Quote:

Originally Posted by IcEWoLF

Very nice charles, that looks amazing!

Thanks IceWoLF - Welcome to XS. :)

Quote:

Originally Posted by Yil

Hi Charles,
when will they be available in the Murdermod shop??

Gr Yil

Hey Yil my friend. :)

I don't think they will be a regular stocked item. Perhaps special order... ;)

Quote:

Originally Posted by ultimeus

Nice update Charles, I see murderbox signature on this too ;)

Cheers ultimeus! :)

Quote:

Originally Posted by dingdong555

Charles my friend, you're work is beyond outstanding. I'd kill to see what you can do to case in 10years ;)

Perfectionist......that you are spedo man!

Thank you James. :)

You won't have to wait 10 years. As for the killing part - well, it is murderbox... ;)

Quote:

Originally Posted by hiiyah777

Looking brilliant as always, Charles!!!

Cheers Jason! :)

Quote:

Originally Posted by moogle

:D

Nice to see more great work by you charles :up:

Cheers moogle - your avatar is one of my favorite cat pics! :)

Quote:

Originally Posted by dsecrieru

I love big updates! :D

Awesome display of your skills and tools man. It's all coming together quite nicely. I can even see the Light at the end of the... tunnel, yes tunnel. ;)

Daniel.

P.S. I hope your health's better and the flu is gone.

Cheers Daniel - feeling a bit better thanks. Still not 100% so I'll have to reluctantly take it easy this week... something I hate having to do. I'm used to running at one speed.

We'll get there my friend. :)

Quote:

Originally Posted by Dangals

Charles you are a wonder - you make everything look so incredibly simple and on top of that you make it easy (and enjoyable) for everyone to follow. :clap:

My hat of to you sir :yepp:

Thank you Daniel, I really appreciate your kind words. The beauty of the worklog is that you don't see me measuring the same thing 10 times. Anyone watching me work would surely loose their marbles! "just cut the damn thing...!" they'd say. :ROTF:

Quote:

Originally Posted by SNiiPE_DoGG

Charles I take it you have your waterjet machine recently setup so there is very little damage to the slats on the bed, or do you use a protection coating? the one I have to work with here at school is very torn up and it rips the finish on the panel up.

Sniipe my man, I'm going to pass on my secret but you have to promise not to tell anyone...

Styrofoam.

:)

Quote:

Originally Posted by theseeker

Charles,

In addition to your other many talents, it is apparent that you are jigmeister too! Beautiful work my friend!

Cheers Rocky. :)

I'm a huge fan of jigs! Makes for a lot of setup time but IMHO, always pays off. :yepp:
01-12-2009, 04:45 PM
HuffPCair

I wish I had skill like this. Amazing build so far, looking real good.
01-12-2009, 04:52 PM
twwen2

Amazing work Charles, simply wonderful! :cool:
01-13-2009, 12:13 PM
dualbrain

Very good fit of the double-plate-display combo. :)
01-13-2009, 12:39 PM
masxerofkartis

What's that bit you keep attatching to the jigsaw and what is its use? Other than the blade ofcourse
01-13-2009, 01:22 PM
elite.ire

nice work :up: i was wondering for a while there why you had made two of them alu panels, but alas all is now clear :D :up:
01-13-2009, 03:16 PM
jimmyxxx

dam fugly work :), just kidding, you know that i know you are the best :D.
01-13-2009, 07:46 PM
Groveling_Wyrm

AMAZING attention to detail, Charles! This should be yet another beautiful creation for you.

Thanx for sharing with us!
01-13-2009, 10:55 PM
PaRn ssR

amazing TJ07. dream of the Temjin :clap:
01-13-2009, 11:11 PM
charles_h

Cheers Guys!

I really appreciate your words of support - they totally motivate me. :)

Quote:

Originally Posted by masxerofkartis

What's that bit you keep attatching to the jigsaw and what is its use? Other than the blade ofcourse

Sorry, which piece are you referring to?

Project Update:

Now that the PLED is in place and the display screen is flush with the plate exterior, I’ll get a reading of the minimum clearance, Clarence.

http://www.murderbox.com/uploads/DS.mM.053.jpg

http://www.murderbox.com/uploads/DS.mM.054.jpg

23mm; Ok.

And the standoffs…

http://www.murderbox.com/uploads/DS.mM.055.jpg

25.4mm… I’ll have to remove about 2mm of material.

I could use a grinder but like doing it old school – with a piece of Emory cloth. I have more control this way and can give myself a fairly decent manicure while I’m at it!

http://www.murderbox.com/uploads/DS.mM.056.jpg

Using Emory cloth will allow for greater control of the amount of material removed while keeping the end flat.

After a few minutes of vigorous… errr… stroking…

http://www.murderbox.com/uploads/DS.mM.057.jpg

Bingo! - now I just have to do the same for the other 5.

The next step is to drill the mounting holes. I’ll keep the vertical positions consistent with the PLED mount holes. Horizontally, the three sets of holes will be positioned to make the best contact with the existing TJ07 vertical structure – while not getting in the way of mounting hard drives. I don’t want to limit Daniel’s drive mount options or interfere with the location of the optical drive. A bit of measuring and figuring will do the trick. Once completed, I’ll drill the 6 mounting holes and then countersink them.

http://www.murderbox.com/uploads/DS.mM.060.jpg

In case you’re wondering, the notch in the bottom left corner is to accommodate a threaded fitting in the corner of the midplate – you won’t see the notch when the piece is in place.

http://www.murderbox.com/uploads/DS.mM.064.jpg

Next, I’ll install the standoffs.

http://www.murderbox.com/uploads/DS.mM.061.jpg

The black “washer” looking thingies were provided by Nils. Because of having to countersink the screws, I needed something on the backside to offset the small portion at the base of the tapered screw head that came through the hole. Without them, the cylindrical offsets would contact the base of the screw head before the plate. These little fellas saved my bacon. (Thanks Nils!).

http://www.murderbox.com/uploads/DS.mM.063.jpg

The PLED mount is pretty much done.

Now, I’ll move to the facade piece (not to be confused with codpiece). Since the angled edge is longer than needed, I’ll remove the excess material. The goal is to end up with the short, right angled section of the facade making flush contact with the outer edge of the existing TJ07 vertical structure.

http://www.murderbox.com/uploads/DS.mM.058.jpg

I’ll overlap the facade with the TJ07 part and mark it for cutting.

http://www.murderbox.com/uploads/DS.mM.066.jpg

http://www.murderbox.com/uploads/DS.mM.065.jpg

http://www.murderbox.com/uploads/DS.mM.059.jpg

Before cutting, honor must be paid to the lucky Zen Frog (I know, I know…).

http://www.murderbox.com/uploads/DS.mM.017.jpg

After cutting and cleaning up with my bastard file…

http://www.murderbox.com/uploads/DS.mM.067.jpg

Sweet success!

Next, I’ll secure the facade to the PLED mount by using 4 countersunk flat head M3 screws. They’ll be placed at the top and bottom and should be discreet when all is done. On the back of the PLED plate, I will epoxy 4 nylon locking nuts so that Daniel can remove the whole unit from the outside.

http://www.murderbox.com/uploads/DS.mM.069.jpg

http://www.murderbox.com/uploads/DS.mM.070.jpg

http://www.murderbox.com/uploads/DS.mM.071.jpg

Once powder coated, the screws should blend nicely.

The next and final step is to line up the standoffs and attach them to the TJ07 vertical structure. I’ll use a paper template to transfer the standoff positions; then I’ll mark and drill the holes.

http://www.murderbox.com/uploads/DS.mM.072.jpg

All 6 holes are drilled.

Wouldn’t you know it! My camera battery died just as I was going to take shots of it all together. Tune in tomorrow to see how it turned out!

Ok, that was cruel – I did manage to squeeze off one shot before it croaked – from the inside. ;)

http://www.murderbox.com/uploads/DS.mM.073.jpg

Thanks for looking in. :)
01-13-2009, 11:58 PM
dsecrieru

Haha, that was cruel! :D

Awesome attention to details, Charles!

Daniel.

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