Case Mods - New custom acrylic case -- Worklog to come

I've been working on a Custom acrylic PC case that I designed.

Case features a double sidewall to allow intake air without the need of front holes; also good for cable routing. Designed to hold 2 360mm Radiators; will only use one ATM with a Y-line loop. Stealthed CD slot; will wire the eject button and activity LED to an illuminated pushbutton to preserve the clean look of the front panel.

Here are some pics of the 3D model in it's current state. I'll update with pics of the actual build as well.

http://ocidb.com/albums/userpics/10005/PC1.jpg

http://ocidb.com/albums/userpics/10005/PC2.jpg

http://ocidb.com/albums/userpics/10005/PC3.jpg

http://ocidb.com/albums/userpics/10005/PC4.jpg

http://ocidb.com/albums/userpics/10005/PC5.jpg

Expected Hardware Requirements:
DFI Lanparty UT 680i SLI T2R/G ---- Out of pocket
Intel Q6600 G0 ---- Out of pocket
Creative X-Fi XtremeGamer ---- Out of pocket
2x BFG 8800GTX ---- Out of pocket
2x1Gb DDR2 RAM (been eying the Corsair Dominator PC2-10000)
Lite-On SATA DVD burner ---- Out of pocket
Silverstone ST1000 Modular PSU ---- Out of pocket
500+Gb SATA2 HDD ---- Out of pocket
2x X-Flow Black Ice Extreme III ---- Sponsored by DangerDen
Variable speed D5 ---- Sponsored by DangerDen
20 feet 1/2" ID Tygon ---- Sponsored by DangerDen
2x Brass Fill-port ---- Sponsored by DangerDen
TDX for LGA775 ---- Sponsored by DangerDen
Maze4 chipset block (regular block) ---- Sponsored by DangerDen
875 chipset block ---- Sponsored by DangerDen
2x 8800 GTX blocks ---- Sponsored by DangerDen
2x single-slot PCI bracket for the 8800s ---- Sponsored by DangerDen
Fill-port Reservoir ---- Sponsored by DangerDen
6x 120mm Case Fans ---- Sponsored by A.C.Ryan
Wire-sleeving ---- Sponsored by A.C.Ryan
2x dual 30cm red CCFLs ---- Sponsored by A.C.Ryan
dual 30cm UV CCFLs ---- Sponsored by A.C.Ryan
dual 20cm UV CCFLs ---- Sponsored by A.C.Ryan
Acrylic Case feet ---- Sponsored by Petra's Tech Shop
H2O Dies ---- Sponsored by Petra's Tech Shop
Biocide H2O additive ---- Sponsored by Petra's Tech Shop
AS5 ---- Sponsored by Petra's Tech Shop
36" SATA2 cables ---- Sponsored by Petra's Tech Shop


Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

woot awesome i definitely wanna see that


and WOOOOOOOOOOOOOOOOT 1000th post!

I spent last night and today working on the motherboard panel.

Sketched panel in Pro/E
http://ocidb.com/albums/userpics/10005/MB-Panel.JPG

Masked the Acrylic sheet and marked the locations for the MB standoffs, RAD, and Front-panel port mounts.
http://ocidb.com/albums/userpics/10005/MB-Panel1.jpg

With old MB to verify markings
http://ocidb.com/albums/userpics/10005/MB-Panel2.jpg

Drilled pilot holes
http://ocidb.com/albums/userpics/10005/MB-Panel3.jpg

Cutting the fan/RAD holes
http://ocidb.com/albums/userpics/10005/MB-Panel4.jpg

Finished fan/Rad holes
http://ocidb.com/albums/userpics/10005/MB-Panel5.jpg

Drilled out holes to secure the RAD
http://ocidb.com/albums/userpics/10005/MB-Panel6.jpg

Illustration of MB standoff mounting
http://ocidb.com/albums/userpics/10005/MB-Panel7.jpg

Drilled out and threaded holes for MB standoffs and FPIO mount
http://ocidb.com/albums/userpics/10005/MB-Panel8.jpg

Unmasked panel
http://ocidb.com/albums/userpics/10005/MB-Panel9.jpg

Mounting of FPIO
http://ocidb.com/albums/userpics/10005/MB-Panel10.jpg

Added slots for cable pass-through. All cabling will be routed underneath the MB panel
http://ocidb.com/albums/userpics/10005/MB-Panel11.jpg

Test fit of my current MB and FPIO ports
http://ocidb.com/albums/userpics/10005/MB-Panel12.jpg

http://ocidb.com/albums/userpics/10005/MB-Panel13.jpg

I don't have the new RAD/fans yet so I couldn't test fit those.

If anyone would like to see other detail shots/angles please LMK

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

u do amazing design\build work!!!

but to bad u already scratched the plexiglass sheets up beyond repair.u have a good quality camera and i can see em all.i built a few plexiglass cases myself(kits)and thee slighest scratch u get,your screwed cause they stick out from a mile away.and from the looks of those sheets slammed on that horse u scracthed em up REAL good.sheets should always be placed on a clean tshirt etc...not wooden horses(atleast cover the horses)

my old p4..plain jane yes,but cool 4 years ago
http://s76.photobucket.com/albums/j1...older_p4-1.jpg

my buddys current case now,e6600,8800gts,raptors..its %100 scratchless minus 1 tiny scratch in the back.we used cotton gloves putting it together.
http://s76.photobucket.com/albums/j1...t=edsstuff.jpg

http://s76.photobucket.com/albums/j1...=edssikrig.jpg

http://s76.photobucket.com/albums/j1...t=eds_p4_4.jpg

http://s76.photobucket.com/albums/j1...dsbasement.jpg

every second u touch these,u must be uber careful cause end result after putting it all togther the scratches show up so easily and its ruined.either ccfl\neon\uv bulbs show scratches 10x more no matter what bulb type or color u use..

incredible clear acrylic case deal $80
http://www.svc.com/acuf-huvb.html

What speed setting did you have on your dremel when cutting the fan holes?

Quote:

---

Originally Posted by railmeat

u do amazing design\build work!!!

but to bad u already scratched the plexiglass sheets up beyond repair.u have a good quality camera and i can see em all.i built a few plexiglass cases myself(kits)and thee slighest scratch u get,your screwed cause they stick out from a mile away.and from the looks of those sheets slammed on that horse u scracthed em up REAL good.sheets should always be placed on a clean tshirt etc...not wooden horses(atleast cover the horses)

my old p4..plain jane yes,but cool 4 years ago
http://s76.photobucket.com/albums/j1...older_p4-1.jpg

my buddys current case now,e6600,8800gts,raptors..its %100 scratchless minus 1 tiny scratch in the back.we used cotton gloves putting it together.
http://s76.photobucket.com/albums/j1...t=edsstuff.jpg

http://s76.photobucket.com/albums/j1...=edssikrig.jpg

http://s76.photobucket.com/albums/j1...t=eds_p4_4.jpg

http://s76.photobucket.com/albums/j1...dsbasement.jpg

every second u touch these,u must be uber careful cause end result after putting it all togther the scratches show up so easily and its ruined.either ccfl\neon\uv bulbs show scratches 10x more no matter what bulb type or color u use..

incredible clear acrylic case deal $80
http://www.svc.com/acuf-huvb.html

---

Actually my first modding project and first real 3D model/assembly (only other 3D work I've done was for a Pro/E class I took this summer).

Thanks for the tip on the T-shirts. At least this is the only panel I've started working on (and it'll be inside). I do plan on polishing it with Novus Plastic polish and maybe with the Novus fine scratch remover to remove any scratches.

Any other tips are most welcome.

Quote:

---

Originally Posted by SP1

What speed setting did you have on your dremel when cutting the fan holes?

---

5-7 seemed to work real well. I then used some fine sandpaper to make sure it was nice and smooth.

Edit: BTW I was using the bits from the router attachment.

Today I started working on the drive Bays:
http://ocidb.com/albums/userpics/100..._Drive_Bay.JPG

http://ocidb.com/albums/userpics/100..._Drive_Bay.JPG

Laid out the parts on the masked acrylic:
http://ocidb.com/albums/userpics/10005/Drive-Bays1.jpg

The cut out panels:
http://ocidb.com/albums/userpics/10005/Drive-Bays2.jpg

Threaded side panels for drive retention mechanism (will into detail on that later):
http://ocidb.com/albums/userpics/10005/Drive-Bays3.jpg

Cut drive support rails:
http://ocidb.com/albums/userpics/10005/Drive-Bays4.jpg

Unmasked 5 1/4 bay panels:
http://ocidb.com/albums/userpics/10005/Drive-Bays5.jpg

Unmasked 3 1/2 bay panels:
http://ocidb.com/albums/userpics/10005/Drive-Bays6.jpg

I have to wait on an order from US Plastics before I can glue these parts together.

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

DAMN

I really gotta get a hole saw attachment 4 my dremel. That looks a lot easier than my regular drill attachment hole saw that i used for my acrylic window. I was so close to cracking the window the entire time i used it. Thankfully I didn't.

Oh and btw two questions.

1. How did you cut the long tunnels for the wires?
2. What bit did u use while using the hole cutting attachment.

Quote:

---

Originally Posted by ineedaname

DAMN

I really gotta get a hole saw attachment 4 my dremel. That looks a lot easier than my regular drill attachment hole saw that i used for my acrylic window. I was so close to cracking the window the entire time i used it. Thankfully I didn't.

Oh and btw two questions.

1. How did you cut the long tunnels for the wires?
2. What bit did u use while using the hole cutting attachment.

---

1) I used the router attachment for the slots http://www.dremel.com/en-us/attachme...=69679&I=69795
2) One of their cutting bits that came with the router attachment http://www.dremel.com/en-us/attachme...188549&G=66357

The slots didn't turn out perfectly; so the next ones I'll use my jigsaw on the straight sections and either just finish the rounds with the Dremel; or I may even cut the rounds first with a spade-bit drill the cut the straights.

Minor update:
Been busy with work the past few days and haven't gotten much done on the case. The good news is that DangerDen is on board to sponsor the Liquid cooling aspect of this case build

wow looking good :up:

Today I received the 1" Acrylic cubes that I'll use to assemble the main panels of the case
http://ocidb.com/albums/userpics/100...ner_Block1.jpg

Drilled/Tapped the cubes so that I could screw on the panels
http://ocidb.com/albums/userpics/100...ner_Block2.jpg

Closeup of one cube
http://ocidb.com/albums/userpics/100...ner_Block3.jpg

Next I polished the parts for the 3.5" drive bay
http://ocidb.com/albums/userpics/10005/Drive-Bays7.jpg

3.5" Drive bays clamped and glued
http://ocidb.com/albums/userpics/10005/Drive-Bays8.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Sweet nice cubes

I'm guessing ur using them 2 hold the walls together?

Would b cool if u had something like that for the on/reset switches too

Quote:

---

Originally Posted by ineedaname

Sweet nice cubes

I'm guessing ur using them 2 hold the walls together?

Would b cool if u had something like that for the on/reset switches too

---

Thanks ;)

Yep; the cubes are going into the eight corners on the box to connect the main panels.

I'm actually waiting on some LED illuminated pushbutton switches that I'll be using for power, CD eject, and case lighting. They'll be mounted along the right side of the front panel (between the MB panel and the side panel).

Eager to see this one when its done.:up:

Quote:

---

Originally Posted by phelan1777

Eager to see this one when its done.:up:

---

Thanks I'm quite anxious to finish it myself.

Finished the 3 1/2" drive bays
http://ocidb.com/albums/userpics/10005/Drive-Bays9.jpg

Drive retention mechanism; screws on one side with nylon spacers on the ends
http://ocidb.com/albums/userpics/10005/Drive-Bays10.jpg

Test fit with old drive
http://ocidb.com/albums/userpics/10005/Drive-Bays11.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Looks awesome! Can't wait to see finished product.

Me too, very nice:up:

Polished 5 1/4" drive bay panels
http://ocidb.com/albums/userpics/10005/Drive-Bays12.jpg

5 1/4" bay panels glued together
http://ocidb.com/albums/userpics/10005/Drive-Bays13.jpg

Finished 5 1/4" Drive Bays
http://ocidb.com/albums/userpics/10005/Drive-Bays14.jpg

I also polished the MB panel
http://ocidb.com/albums/userpics/10005/MB-Panel14.jpg

Laid out side, front, and back panels
http://ocidb.com/albums/userpics/100...er-Panels1.jpg

Cut out front/back panels
http://ocidb.com/albums/userpics/100...er-Panels2.jpg

Cut out side panel
http://ocidb.com/albums/userpics/100...er-Panels3.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

It looks really nice so far, all of your cuts have been super clean and I can't wait to see the final product.

If you don't mind me asking, how much are you paying for your acrylic? It seems that alot of the members of the forum (especially from America) pay ridiculous prices for acrylic.

Quote:

---

Originally Posted by .Logic

It looks really nice so far, all of your cuts have been super clean and I can't wait to see the final product.

If you don't mind me asking, how much are you paying for your acrylic? It seems that alot of the members of the forum (especially from America) pay ridiculous prices for acrylic.

---

Thanks!!!

I bought 3 610x1220x5 mm (24x48x0.2 in) sheets for ~$30US each. Mind you, this was Acrylic and Lexan is more expensive.

Is it not enough to glue everything to each other.
I see you are using cubes , is this really needed?

Quote:

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Originally Posted by sssf

Is it not enough to glue everything to each other.
I see you are using cubes , is this really needed?

---

I'm only using the cubes in the eight corners of the case to screw the outer panels together. I don't want everything glued because I wouldn't be able to get in there.

Yea glue usually doesn't look very good either cuz it leaves a white residue

Just a small update; should have more by the weekend
Looks like A.C. Ryan may be providing some sponsorship as well.
Laid out top, bottom, and other side panel
http://ocidb.com/albums/userpics/100...er-Panels4.jpg

Cut out top and bottom panels
http://ocidb.com/albums/userpics/100...er-Panels5.jpg

Cut out side panel
http://ocidb.com/albums/userpics/100...er-Panels6.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Quote:

---

Originally Posted by radodrill

I'm only using the cubes in the eight corners of the case to screw the outer panels together. I don't want everything glued because I wouldn't be able to get in there.

---

whehe, thats quite smart :up:

:am:

Drilled screwholes into the first side panel
http://ocidb.com/albums/userpics/100...er-Panels7.jpg

Same for the other side panel
http://ocidb.com/albums/userpics/100...er-Panels8.jpg

Screwholes and fill-port hole in the top panel
http://ocidb.com/albums/userpics/100...er-Panels9.jpg

Introducing the Dremel's big brother :D
http://ocidb.com/albums/userpics/100...r-Panels10.jpg

Screwholes, drainport, and air intake slots in the bottom panel
http://ocidb.com/albums/userpics/100...r-Panels11.jpg

Test-fit assembled outer panels; had to sand some of the corner blocks and panels to achieve a perfect fit
http://ocidb.com/albums/userpics/100...r-Panels12.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

:eek2: :eek2: :eek2:

whats the name of that program you are using to design the case?

Quote:

---

Originally Posted by hecktic

:eek2: :eek2: :eek2:

whats the name of that program you are using to design the case?

---

I'm using Pro/E Wildfire 3.

Yesterday I received the pushbutton switches for this case; some ring-illuminated momentary switches, dot-illuminated latching switches, and a non-illuminated momentary switch
http://ocidb.com/albums/userpics/10005/Pushbuttons.jpg

I added some stops to the panels to ensure flush edges
http://ocidb.com/albums/userpics/100...r-Panels13.jpg

Laid out the back panel
http://ocidb.com/albums/userpics/100...r-Panels14.jpg

Cut out back panel
http://ocidb.com/albums/userpics/100...r-Panels15.jpg

Fitted into the back of the case
http://ocidb.com/albums/userpics/100...r-Panels16.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Damn this is going to look nice :) I love those switches

Quote:

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Originally Posted by Cupcake

Damn this is going to look nice :) I love those switches

---

Thanks man!

And to think, all 7 switches together cost me ~$22; compared to ~$20 for an anti-vandal switch (and they're not available as latching switches :confused: )

Where did you order them from ? (sorry if you posted this somewhere else I only look at pictures lol)

Quote:

---

Originally Posted by Cupcake

Where did you order them from ? (sorry if you posted this somewhere else I only look at pictures lol)

---

Ordered them from http://www.sunshinele.com/htm/pushbutton_switch.html

Datasheet: http://www.sunshinele.com/down/as2gq.pdf

If I had opted for express DHL shipping it would have been an additional $58 :( But at least that would still have been less than buying ant-vandals.

Contact email I used was: sunshine @ sunshinele . com

Awesome thanks for the link <3

Quote:

---

Originally Posted by Cupcake

Awesome thanks for the link <3

---

YW; if you're planning on doing a lot of modding you might as well stock up ;)

I have been looking fro a white lighted switch, thank you for posting.


This is seriously giving me the urge to look into building my own acrylic case.

I have the tools, and the place and time, just not the money to spend on acrylic :-P.

I am still stuck on the idea of a Delrin case ;).

[QUOTE=radodrill;2370928][B]Yesterday I received the pushbutton switches for this case; some ring-illuminated momentary switches, dot-illuminated latching switches, and a non-illuminated momentary switch
http://ocidb.com/albums/userpics/10005/Pushbuttons.jpg


Wow those switches look good ; did you get them from performance PC-s

Quote:

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Originally Posted by mukmaster

Wow those switches look good ; did you get them from performance PC-s

---

I got them from Sunshine Electric; links are a few posts up

Quote:

---

Originally Posted by phelan1777

I have been looking fro a white lighted switch, thank you for posting.


This is seriously giving me the urge to look into building my own acrylic case.

I have the tools, and the place and time, just not the money to spend on acrylic :-P.

I am still stuck on the idea of a Delrin case ;).

---

Yeah; go for building your own case. From what I've seen Delrin is more expensive that acrylic, but polished black sure would look cool.

Quote:

---

Originally Posted by radodrill

Yeah; go for building your own case. From what I've seen Delrin is more expensive that acrylic, but polished black sure would look cool.

---

I have been an advocate for a Delrin case for a while I know it would be like 300-400 just for 4 sheets of 24X48" I already looked into it.

I want to do it so bad...........its eating @ me, just don't have the money for the DELRIN, nor the skill to make all the cuts right the first time.

Quote:

---

Originally Posted by phelan1777

I have been an advocate for a Delrin case for a while I know it would be like 300-400 just for 4 sheets of 24X48" I already looked into it.

I want to do it so bad...........its eating @ me, just don't have the money for the DELRIN, nor the skill to make all the cuts right the first time.

---

A Delrin case probably would look cool; probably cuts muck like acrylic, just go slow and steady.

p.s. this is my first time working with acrylic and I got it correct right from the start.

This Morning I received a package from A.C. Ryan containing fans, CCFLs, and wire sleeving supplies
http://i116.photobucket.com/albums/o...ct/ACRyan1.jpg

Time for some eye-candy :D
Kameleon Fan; translucent black under normal light
http://ocidb.com/albums/userpics/10005/ACRyan2.jpg

And Blue under UV
http://ocidb.com/albums/userpics/10005/ACRyan3.jpg

With the fan on:
http://ocidb.com/albums/userpics/10005/ACRyan4.jpg

Red Twin Overburst CCFLs
http://ocidb.com/albums/userpics/10005/ACRyan5.jpg

UV Twin Overburst CCFLs
http://ocidb.com/albums/userpics/10005/ACRyan6.jpg

And the money shot :D
Fan and wire sleeving in full UV splendor:
http://ocidb.com/albums/userpics/10005/ACRyan7.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Long awaited update :D

Laid out Front Panel
http://ocidb.com/albums/userpics/100...r-Panels17.jpg

Cut out Front Panel
http://ocidb.com/albums/userpics/100...r-Panels18.jpg

Assembled Outer Panels

http://ocidb.com/albums/userpics/100...r-Panels19.jpg

Rounded the edges; note, only the outside edges have rounds
Top and Bottom Panels
http://ocidb.com/albums/userpics/100...r-Panels20.jpg

Front and Back Panels
http://ocidb.com/albums/userpics/100...r-Panels21.jpg

Left Panel
http://ocidb.com/albums/userpics/100...r-Panels22.jpg

Right Panel
http://ocidb.com/albums/userpics/100...r-Panels23.jpg

Tomorrow I'll put it back together and sand all the edges and blend the corners. I hope to get it polished tomorrow as well; But I may work on a wheeled base for it

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

your case is really starting to come together, in a great way :)

Quote:

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Originally Posted by The_Beast

your case is really starting to come together, in a great way :)

---

Thanks, I've still got a fair amount of work to go; but I like the way it's turning out.

Sweet! Normally I'm not a big fan of acrylic cases, but custom mods are always awesome in my book. Keep up the great work!

Quote:

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Originally Posted by The Ripe Punani

Sweet! Normally I'm not a big fan of acrylic cases, but custom mods are always awesome in my book. Keep up the great work!

---

Thanks Man!

I'm not a fan of the Acrylic cases on the market; IMO they're not "user-friendly"

Just a small update today; but it give a good perspective of what the finished product will look like

Sanded the edges to blend the corners together
http://ocidb.com/albums/userpics/100...r-Panels24.jpg

Assembled the panels with switches and FPIO to give an idea of how the case will look
http://ocidb.com/albums/userpics/10005/Case1.jpg

I still have to polish up the edges and install the drive bays; then the case itself will be basically complete.

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Brilliant job Radodrill.
Best of luck with it !!!!!!!!!!

Quote:

---

Originally Posted by cian1500ww

Brilliant job Radodrill.
Best of luck with it !!!!!!!!!!

---

Thanks Man!

IMO it's shaping up nicely.

I really like the layout and design of your case :up: Between your acrylic case and Colossous's splash-anodised case, i think i might consider a case for my future o/c rig :D Looks awesome! :clap:

danm fine jop radodrill you project looks amazing so far.. and i cant wait to see it finished :up: keep the updates coming mate.

I've also received support from Petra's Tech Shop

Here's what they sent me: Acrylic LED case feet, 3x 120mm chrome fan grills, and water additives (Biocide & Blue, Green, and Red dyes)
http://ocidb.com/albums/userpics/10005/PTS1.jpg

The LED feet and wiring harnesses
http://ocidb.com/albums/userpics/10005/PTS2.jpg

Case feet in action
http://ocidb.com/albums/userpics/10005/PTS3.jpg

One drawback to the controller for the LEDs is that it defaults to a flashing mode when it's turned on; but I'll be eliminating the controller and connecting them directly to a switched 12V line, so that won't be an issue for me.

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Great job..... congract.... i think that you have a goob hand to do thing like this..

Some progress pics are missing since one of my memory cards died

Polished the edges of the outer panels
http://ocidb.com/albums/userpics/100...r-Panels25.jpg

http://ocidb.com/albums/userpics/100...r-Panels26.jpg

http://ocidb.com/albums/userpics/100...r-Panels27.jpg

http://ocidb.com/albums/userpics/100...r-Panels28.jpg

Also installed the PCI mounting bracket
http://ocidb.com/albums/userpics/100...r-Panels29.jpg

http://ocidb.com/albums/userpics/100...r-Panels30.jpg

Cut out/polished the CD slot cover
http://ocidb.com/albums/userpics/10005/Drive-Bays15.jpg

Placed in the slot on the front panel
http://ocidb.com/albums/userpics/10005/Drive-Bays16.jpg

Made some side pieces for the 5 1/4" bay
http://ocidb.com/albums/userpics/10005/Drive-Bays17.jpg

Glued them into place
http://ocidb.com/albums/userpics/10005/Drive-Bays18.jpg

With a drive in place
http://ocidb.com/albums/userpics/10005/Drive-Bays19.jpg

This evening I'll mount the drive bays; so stay tuned for another update

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Another update; The case itself is finished so next I'll have to make the base and do the wiring

Cut acrylic pieces for mounting the drive bays
http://ocidb.com/albums/userpics/10005/Drive-Bays20.jpg

Polished the mounting pieces
http://ocidb.com/albums/userpics/10005/Drive-Bays21.jpg

Glued the mounting pieces to the drive bays
http://ocidb.com/albums/userpics/10005/Drive-Bays22.jpg

Gluing the drive bays together
http://ocidb.com/albums/userpics/10005/Drive-Bays23.jpg

Finished Drive Bays
http://ocidb.com/albums/userpics/10005/Drive-Bays24.jpg

Lining up the drive bays on the top panel
http://ocidb.com/albums/userpics/10005/Drive-Bays25.jpg

Drilled screwholes at the front of the drive bays
http://ocidb.com/albums/userpics/10005/Drive-Bays26.jpg

Drilled out holes in top panel
http://ocidb.com/albums/userpics/10005/Drive-Bays27.jpg

Tapped holes in the drive bays
http://ocidb.com/albums/userpics/10005/Drive-Bays28.jpg

Screwed them together
http://ocidb.com/albums/userpics/10005/Drive-Bays29.jpg

Drilled holes at the back of the drive bays
http://ocidb.com/albums/userpics/10005/Drive-Bays30.jpg

Drilled out the holes in the top panel
http://ocidb.com/albums/userpics/10005/Drive-Bays31.jpg

Several shots of the assembled case
http://ocidb.com/albums/userpics/10005/Case2.jpg

http://ocidb.com/albums/userpics/10005/Case3.jpg

http://ocidb.com/albums/userpics/10005/Case4.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Quote:

---

Originally Posted by radodrill

http://ocidb.com/albums/userpics/10005/ACRyan1.jpg

---

This picture is so amazing. I'm just dr00ling :D

/subscribed

Very nice work and highly impressive at that :clap: . Good luck with the rest of this, can't wait to see the final product.

Quote:

---

Originally Posted by Alik4041

This picture is so amazing. I'm just dr00ling :D

/subscribed

Very nice work and highly impressive at that :clap: . Good luck with the rest of this, can't wait to see the final product.

---

Thanks a lot; I'm very happy with the support I've received so far.

crazy nice project man. want to see this completed. how thick is the stuff you are using? I planned on doing one but what I considered good enough was 1/4" and it would have cost me a lot of money.

Wanted something super strong knowing me it needs to be twice as strong as it normally should

Quote:

---

Originally Posted by TorquedJetta

crazy nice project man. want to see this completed. how thick is the stuff you are using? I planned on doing one but what I considered good enough was 1/4" and it would have cost me a lot of money.

Wanted something super strong knowing me it needs to be twice as strong as it normally should

---

Thanks man; the acrylic I have is sold as 0.220" (5mm) thick; anything thinner and you'd need a support frame.

Quote:

---

Originally Posted by railmeat

but to bad u already scratched the plexiglass sheets up beyond repair.

---

For the record; the sheets must have had the scratches when I got them form Lowe's (as other sheets had scratches even so they had a plastic film on them).

I did find an excellent way of removing scratches (even deep ones) and still have a mirror finish. Remove the scratch by sanding it out with 120Grit; then wet sand that area with 600Grit; finally polish with Novus #2 using a cloth buffing wheel. :up:

I finished making my PWM fan and lighting controller. It has 8 fan channels and 4 lighting channels (1 dedicated to the fan lighting). The fan LEDs are connected to separate headers from the fan itself.

First: the circuit I used
http://ocidb.com/albums/userpics/100...ol_circuit.jpg

Installed 1 fan control channel to work out the layout
http://ocidb.com/albums/userpics/100...n_control1.jpg

Here in the US I wasn't able to find anyplace that had the MIC502 fan control IC available in a DIP package; so I had to make due with the SMD version
http://ocidb.com/albums/userpics/100...n_control2.jpg

Soldering on leads
http://ocidb.com/albums/userpics/100...n_control3.jpg

1 DIPicized IC
http://ocidb.com/albums/userpics/100...n_control4.jpg

All eight channels integrated on the PCB
http://ocidb.com/albums/userpics/100...n_control5.jpg

Added power supply as well as headers for the fan LEDs and fan LED switch
http://ocidb.com/albums/userpics/100...n_control6.jpg

Also installed headers for the case lighting control
http://ocidb.com/albums/userpics/100...n_control7.jpg

And a pass-through MOLEX connector
http://ocidb.com/albums/userpics/100...n_control8.jpg

The underside of the controller
http://ocidb.com/albums/userpics/100...n_control9.jpg

The wiring for the power connectors will also be sleeved later on in the project.

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

wow man you do very great work. thats a lot of soldiering. the case is lookin very nice to. lookin forward to seeing it done and all lit up.

Quote:

---

Originally Posted by natedog420

wow man you do very great work. thats a lot of soldiering. the case is lookin very nice to. lookin forward to seeing it done and all lit up.

---

Thanks man; it took about a day to make the fan controller. Man was that fun :p:

BTW the molex pass-through will go to the pump.

Sleeved the wiring on the fan contoller
http://ocidb.com/albums/userpics/100..._control10.jpg

I also wired up and sleeved the switches for the case lighting as well as the power cables for the CCFL inverters
http://ocidb.com/albums/userpics/10005/Cabling1.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

That fan controller is simply amazing. You should teach me some time ;)

Omg, wow is all i can say:clap:

Thanks a lot guys; I'm happy with the way it turned out.

impressive doesnt just cut it

thats a work of art. nice 1! maybe it would be worth you offering to custom build to order a case for people??

im in the market for a new case and if you were in the same country i'd probably harrass you to do me something, paying you for your time of course!

Sleeved the cabling for the front panel IO
http://ocidb.com/albums/userpics/10005/Cabling2.jpg

Changing gears for a while; I cut out the MDF baseboard and rounded the edges
http://ocidb.com/albums/userpics/10005/Base1.jpg

First coat of Lacquer paint
http://ocidb.com/albums/userpics/10005/Base2.jpg

Back to the cabling; Wired up and sleeved the HDD LED, Reset Switch, and Power Switch w/ Power LED
http://ocidb.com/albums/userpics/10005/Cabling3.jpg

Back to the baseboard again; Second coat of paint
http://ocidb.com/albums/userpics/10005/Base3.jpg

Sanded smooth
http://ocidb.com/albums/userpics/10005/Base4.jpg

I'm hoping to be able to get a piano-quality high-gloss finish; thus the use of the lacquer.

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

I'm usually not a fan of acryllic cases but as the gentleman said above, this is a work of art and one can see the love that went into it..
Excellent work and a great read following this.:up:

Quote:

---

Originally Posted by it_burns_when_i_pee

impressive doesnt just cut it

thats a work of art. nice 1! maybe it would be worth you offering to custom build to order a case for people??

im in the market for a new case and if you were in the same country i'd probably harrass you to do me something, paying you for your time of course!

---

Thanks a million!!!

This is actually my first time doing this kind of a project; and first time working with acrylic. The first is always the hardest ;) But I did spend a lot of time planning this in Pro/E (no sketchup here :D)

Maybe some time in the future I can do custom cases as a side business. Right now I'm still in college working on a Masters and employed as a graduate assistant so I usually only have time to work on this on the weekends and some evenings.

Quote:

---

Originally Posted by Movieman

I'm usually not a fan of acryllic cases but as the gentleman said above, this is a work of art and one can see the love that went into it..
Excellent work and a great read following this.:up:

---

Thanks man; I sure put a lot of time into this and I'm trying to get the details as perfect as I can.

Quote:

---

Originally Posted by radodrill

Thanks man; I sure put a lot of time into this and I'm trying to get the details as perfect as I can.

---

Beleive me, it shows. I'm a pretty decent cabinetmaker and I can see the work..;)

you've but alot of patients and thought into it. even if its your first you can see your methodical approach is paying off.

i'm keeping an eye on this thread .... and im serious about offering your services out. could be a nice little side earner for you. cases over here sell upwards of £200 which is well over 400 dollors. for that kind of money i would want a custom case to my needs instead of all this empty room i wouldnt want.

Quote:

---

Originally Posted by it_burns_when_i_pee

you've but alot of patients and thought into it. even if its your first you can see your methodical approach is paying off.

i'm keeping an eye on this thread .... and im serious about offering your services out. could be a nice little side earner for you. cases over here sell upwards of £200 which is well over 400 dollors. for that kind of money i would want a custom case to my needs instead of all this empty room i wouldnt want.

---

I was chewing on ideas for a few months; then spent a few weeks modeling it in Pro/E before I even made a single cut.

I wanted such a big case so that it could easily handle H2O cooling and the latest super-long GFX cards while still giving me good access to the hardware. in my old case it's hard to swap a HDD without first removing the GFX card; and I find that unacceptable.

I absolutely love your build. Everything you've done has been so precise that it boggles the mind. The only gripe i can think of is that I would have preferred the HDD cage to have been reverse mounted to the back panel. So that you would have slid them into position on the connectors at the back panel and be viewing the "butt" of the HDD's from the side view.

just my personal preference, to each his own.

Quote:

---

Originally Posted by mike8913

I absolutely love your build. Everything you've done has been so precise that it boggles the mind. The only gripe i can think of is that I would have preferred the HDD cage to have been reverse mounted to the back panel. So that you would have slid them into position on the connectors at the back panel and be viewing the "butt" of the HDD's from the side view.

just my personal preference, to each his own.

---

I thought about that; but I think it looks better with all the retention screws on the same side of the drive bays.

Now for installing the case feet;

Marked the location of the 8 holes
http://ocidb.com/albums/userpics/10005/Case-Feet1.jpg

Drilled the holes
http://ocidb.com/albums/userpics/10005/Case-Feet2.jpg

Inserted the feet; nice snug fit so no glue necessary
http://ocidb.com/albums/userpics/10005/Case-Feet3.jpg

Started the wiring for the LED illumination of the feet
http://ocidb.com/albums/userpics/10005/Case-Feet4.jpg

Finished wiring the LEDs
http://ocidb.com/albums/userpics/10005/Case-Feet5.jpg

Mounted the fan controller
http://ocidb.com/albums/userpics/10005/Case5.jpg

Now a gallery of the (almost) finished case
http://ocidb.com/albums/userpics/10005/Case6.jpg

http://ocidb.com/albums/userpics/10005/Case7.jpg

http://ocidb.com/albums/userpics/10005/Case8.jpg

http://ocidb.com/albums/userpics/10005/Case9.jpg

http://ocidb.com/albums/userpics/10005/Case10.jpg

http://ocidb.com/albums/userpics/10005/Case11.jpg

I still have to install the CCFLs and H2O items as well as do the custom length wiring (and sleeving) of the fans. Once I get all the hardware into the case I'll do some tidying of the cabling. The one front panel that currently isn't hooked up will be used as eject/activity indicator for the CD drive.

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Looks good. Can't wait to see it all lit up :D

Quote:

---

Originally Posted by Alik4041

Looks good. Can't wait to see it all lit up :D

---

Thanks; Once I get the lighting installed I'll get some good pics.

W00T I received a sponsorship package from DangerDen Today.

Here are the goodies:
http://ocidb.com/albums/userpics/10005/DangerDen1.jpg

2x Black Ice X-Flow Xtreme III radiators with 1/2" barbs
http://ocidb.com/albums/userpics/10005/DangerDen2.jpg

2x 8800 GTX/ULTRA waterblocks with stubby SLI barb and single-slot bracket
http://ocidb.com/albums/userpics/10005/DangerDen3.jpg

2x Brass Fill-ports, 24x Plastic snap hose clamps, and 20' 1/2" ID Tygon tubing
http://ocidb.com/albums/userpics/10005/DangerDen4.jpg

LGA775 TDX CPU block, i875 Maze4 chipset block, Maze4 Chipset block, Lucite 680i top for Maze4 blocks (not exactly sure which top is best for the southbridge of the DFI 680i; so DD was nice enough to send both tops so I can use what fits best)
http://ocidb.com/albums/userpics/10005/DangerDen5.jpg

Finally the variable speed D5 pump
http://ocidb.com/albums/userpics/10005/DangerDen6.jpg

I'll have more progress updates soon; Just wanted to share pics of the new gear.

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Installed the Radiators
http://ocidb.com/albums/userpics/100...ercooling1.jpg

http://ocidb.com/albums/userpics/100...ercooling2.jpg

http://ocidb.com/albums/userpics/100...ercooling4.jpg

Soon to be custom pump mounting bracket
http://ocidb.com/albums/userpics/100...ercooling5.jpg

Bent to shape
http://ocidb.com/albums/userpics/100...ercooling6.jpg

Added pump mounting holes
http://ocidb.com/albums/userpics/100...ercooling7.jpg

Finished bracket
http://ocidb.com/albums/userpics/100...ercooling8.jpg

Bracket attached to the pump
http://ocidb.com/albums/userpics/100...ercooling9.jpg

Pump and 1 fan installed in the case (also sleeved the wiring for them)
http://ocidb.com/albums/userpics/100...rcooling10.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

Quote:

---

Originally Posted by radodrill

[B]W00T I received a sponsorship package from DangerDen Today.

Here are the goodies:
http://ocidb.com/albums/userpics/10005/DangerDen1.jpg

---

You deserve it, Nice job! :up: BTW, that pictures looks to die for :p: I wish I canwake up one day and have all that stuff at my door step :D

Quote:

---

Originally Posted by Alik4041

You deserve it, Nice job! :up: BTW, that pictures looks to die for :p: I wish I canwake up one day and have all that stuff at my door step :D

---

Thanks a lot; hopefully I can get some hardware sponsors as well.

still looking really promising

i remember seeing this acrylic case a while back and the guy had watercooling fitted, so airflow not being a real essential he put loads of shower hoses - you know the metal ringed ones - throughout and illuminated green. reminded me of matrix somehow. anyway was a nice touch. perhaps you could do something like that?

also seen one where this guy painted all of his motherboard and video card with a clear uv reactive paint. it was on that overclockers.com website a good while back. that was nice too.

Mounted and sleeved the fans for the front RAD
http://ocidb.com/albums/userpics/100...rcooling11.jpg

Installed some of the tubing
http://ocidb.com/albums/userpics/100...rcooling12.jpg

Re-installed the drive bays; decided to go with frosted sides on the drive bays
http://ocidb.com/albums/userpics/100...rcooling13.jpg

Shot from the front to better show the run of tubing
http://ocidb.com/albums/userpics/100...rcooling14.jpg

Also tidied up the cabling for the front panel switches
http://ocidb.com/albums/userpics/10005/Cabling4.jpg

2 shots to give an idea how some of the lighting will look
http://ocidb.com/albums/userpics/10005/Case12.jpg

http://ocidb.com/albums/userpics/10005/Case13.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

After testing the PWM fan controller with the Blackfire fans I realized that at low speeds the fans were "growling." By means of trial & error I discovered that if I replace the 0.1uF timing capacitor with a 100pF capacitor (raising the PWM frequency from 30Hz to 30KHz) the symptoms are resolved.

Here's the Baseboard after a few more coats of paint, sanding, and steel wool treatment.
http://ocidb.com/albums/userpics/10005/Base5.jpg

Finished installing the rest of the fans
http://ocidb.com/albums/userpics/100...rcooling15.jpg

Here are some gallery shots of the case; not that I've also installed a fill-port reservoir
http://ocidb.com/albums/userpics/10005/Case14.jpg

http://ocidb.com/albums/userpics/10005/Case15.jpg

http://ocidb.com/albums/userpics/10005/Case16.jpg

http://ocidb.com/albums/userpics/10005/Case17.jpg

http://ocidb.com/albums/userpics/10005/Case18.jpg

http://ocidb.com/albums/userpics/10005/Case19.jpg

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

omg... amazing... at first i was like "he doesnt need all that space" but then i see this and im like "k the extra space is going to good use" lol

sooo jealous right now... u dont even know...

Im gonna start my case mode soon. ive got th design down... but not the material usage yet. I wanna go stainless steel and acrylic... And the fact that im a Laser CNC operator is definatly gonna help me cause i suck with dremel lol

Quote:

---

Originally Posted by iNF3rN0

omg... amazing... at first i was like "he doesnt need all that space" but then i see this and im like "k the extra space is going to good use" lol

sooo jealous right now... u dont even know...

Im gonna start my case mode soon. ive got th design down... but not the material usage yet. I wanna go stainless steel and acrylic... And the fact that im a Laser CNC operator is definatly gonna help me cause i suck with dremel lol

---

Thanks a lot :)

I wish I had access to CNC tools (for that matter a full machine shop) :cool:

Started installing the CCFL Lighting

What will become mounting plates for the CCFL inverters
http://ocidb.com/albums/userpics/10005/CCFLs1.jpg

Drilled Screwholes
http://ocidb.com/albums/userpics/10005/CCFLs2.jpg

Rounded the ends
http://ocidb.com/albums/userpics/10005/CCFLs3.jpg

Polished them up
http://ocidb.com/albums/userpics/10005/CCFLs4.jpg

Drilled & tapped screwholes in the MB Panel
http://ocidb.com/albums/userpics/10005/CCFLs5.jpg

Secured the inverters
http://ocidb.com/albums/userpics/10005/CCFLs6.jpg

Mounted the 4 CCFLs on the right side
http://ocidb.com/albums/userpics/10005/CCFLs7.jpg

Secured the right-hand panel
http://ocidb.com/albums/userpics/10005/Case20.jpg

Lighting on; dim ambient lighting
http://ocidb.com/albums/userpics/10005/Case21.jpg

An assortment of shots in the dark
http://ocidb.com/albums/userpics/10005/Case22.jpg

http://ocidb.com/albums/userpics/10005/Case23.jpg

http://ocidb.com/albums/userpics/10005/Case24.jpg

http://ocidb.com/albums/userpics/10005/Case25.jpg

http://ocidb.com/albums/userpics/10005/Case26.jpg

http://ocidb.com/albums/userpics/10005/Case27.jpg

http://ocidb.com/albums/userpics/10005/Case28.jpg

http://ocidb.com/albums/userpics/10005/Case29.jpg

I'm planning on having the case and hardware wrapped up by the end of the upcoming weekend; finishing up the baseboard may take a little longer though.

Sponsors:
http://ocidb.com/albums/userpics/10005/DangerDen.jpg http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg http://ocidb.com/albums/userpics/10005/PTS.jpg

man, still looking good

only you need a better camera or learn to use the macro function. sort the focus, we cant see it's full glory

Very nice. :up: And congratulations :D
http://www.bit-tech.net/modding/2007...th_sept_2007/4

Quote:

---

Originally Posted by Alik4041

Very nice. :up: And congratulations :D
http://www.bit-tech.net/modding/2007...th_sept_2007/4

---

Thanks; didn't realize I was up for MOTM at Bit-Tech

Thanks Bit-Tech for putting me in the running for the Mod of the Month competition for September 2007; I'm very honored.

Thanks to the community here (and the other forums where this log is posted) for your support

Also, Thanks to DangerDen, A.C.Ryan, and Petra's Tech Shop for their help and sponsorship

Quote:

---

Originally Posted by it_burns_when_i_pee

man, still looking good

only you need a better camera or learn to use the macro function. sort the focus, we cant see it's full glory

---

It's a Sony DSC-F828; maybe the shutter speed is a bit slow for handheld use; for the final shots I'll be using a tripod :)

Quote:

---

Originally Posted by radodrill

It's a Sony DSC-F828; maybe the shutter speed is a bit slow for handheld use; for the final shots I'll be using a tripod :)

---

...just a suggestion: set your camera to Macro + play with ISO 400-600 without flash (if there is enough ambient light), set timer to 10 sec on tripod or bag of coffee beans or green peas (conforms better to whatever angle you want)
...looking forward to next pics:up: