Project: ProtoHype - 23 may

PROTOHYPE

Hey
I'm all new to this forum. Been lurking around for some time though but it's not until now that I realize the real potential of this place. At first I couldn't find a thing.. but then I found this section with the worklogs. I thought I would give it a try to post my ongoing project here since Im looking forward to hear your opinions aswell as to share and recive ideas and tips. This is my first computer related project, and therefore my introduction to watercooling. Even though its my first watercooling setup, im pretty familiar with the basics of watercooling since I've been reading a lot about the subject. But there is nothing as valuable as feedback from the ones who is experienced.

Who am I?? I'm currently in the last steps of completing my design engineering studies att university. Will be finished in a couple of weeks and after that I will be devoting my time to job searching and this project. Ever since I was a little kid I have loved drawing and building things and I still do today. The urge of building things is why I'm doing this project.

This project has actually been going on for quite some time, but I was late to post the log on this forum and therefore, I got some catching up to do. There will be quite a lot of updates in the beginning until I get to the stage I am at the moment. At the beginning of this project, I hadn't access to any real workshop and therefore I decided to invest in my own tools lika a mill and lathe as you will see in the pictures below. Ironicaly a couple of months later I got acess to my schools workshop with a lot bigger tools.

Why ProtoHype? If I'm gonna try to relate it, it's probably because it is supposed to look more like a machine prototype of some sort and I guess the hype could be related to all the totally unnecessary stuff I will put in it to make it geeky enough. It was first intended to be some kind of steampunk theme but it evolved into a more modern kind of steampunk machinery look.



Specifications

Case

• 2 seperate watercooling loops, one out of ALU and one copper
• Custom waterblocks for cpu, nort/south bridge, RAM's, HDD and maybe GPU
• 3x120mm Black Ice Extreme Radiator
• External watertanks
• Front acts as a radiator
• A lot of aluminium

Hardware
So far I have desided to wait with the hardware until most of the case is finished. The hardware I currently got is not top notch, and therefore any potential new hardware is put on hold because any large economical funds are absent at the moment.


And now to the pics.

Here is some of the doodle sketches that have been made. No top of the line sketches, but at least it shows how some of the ideas are developing. As you can see from the paper of choice this is what happens when I'm bored in class.

http://i9.photobucket.com/albums/a10...Hype/001_s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...Hype/002_s.jpg
(CLICK TO ZOOM)

Here is one of the ideas for the foot, not the definit one but a hint of what's in my mind.
http://i9.photobucket.com/albums/a10...ype/002a_s.jpg
(CLICK TO ZOOM)

Here is a simple marker sketch to practice some drawing.
http://i9.photobucket.com/albums/a10...Hype/003_s.jpg
(CLICK TO ZOOM)


Here is some basic 3D renders to get a better understanding of what I'm trying to do. I focused the modeling to the exterior of the main body. I didn't bother to putt much effort into all the details as I think there need to be some moment of surprise to keep a worklog interesting. And some parts are left out because I simply haven't decided what to do yet. As for the case feet.

http://i9.photobucket.com/albums/a10...ype/004a_s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...ype/005b_s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...ype/005a_s.jpg
(CLICK TO ZOOM)


As I mentioned previously I ordered a couple of new tools too be able to fabricate all the bits and pieces I wanted. And if I can't get to the schools workshop, I'll have to build my own .. even if I'll have to spend all my savings.
Here's one of the packages.

http://i9.photobucket.com/albums/a10...Hype/011_s.jpg
(CLICK TO ZOOM)

Tada... a brand new 9x30 lathe
http://i9.photobucket.com/albums/a10...Hype/012_s.jpg
(CLICK TO ZOOM)

Next tool arived like this. Not as brand new. Kind of messy and badly treated..
http://i9.photobucket.com/albums/a10...Hype/013_s.jpg
(CLICK TO ZOOM)

...So while I waited for the electrician, i took some time disassembling, cleaning and repainting it.

http://i9.photobucket.com/albums/a10...Hype/014_s.jpg
(CLICK TO ZOOM)

Finished.. much nicer to work with this
http://i9.photobucket.com/albums/a10...Hype/015_s.jpg
(CLICK TO ZOOM)

That mill weighs 350kg and I had to get it up there on my own. Never thought I would make it but with a lot of elbow grease, some rollers and a bandy stick it's sits where it 's supposed to.
http://i9.photobucket.com/albums/a10...Hype/016_s.jpg
(CLICK TO ZOOM)

Okay now for the Construction of the case itself. Guess the pictures speak for them self.
http://i9.photobucket.com/albums/a10...Hype/006_s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...Hype/007_s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...Hype/008_s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...Hype/009_s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...Hype/010_s.jpg
(CLICK TO ZOOM)

This is the window mod of the DVD-drive. This was created before I had my mill and lathe and it took a lot of blood, sweat and tears. Since I'm such a freak when it comes to the finish of the things I do, I often spend way to much time trying to achieve perfection. I often end up redoing some parts over and over again until I'm satisfied. I'm not kidding when I say I have at least spent 100 hours on this DVD drive.

As you probably notice I have removed the center magnetic ring that is supposed to support the disk from above. This will be added later onto the plexi window because I want the window as big as possible. This proved to be one of the mor time consuming tasks.

But anyway here are the pics

http://i9.photobucket.com/albums/a10...oHype/017s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/018s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/019s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/020s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/021s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/022s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/023s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/024s.jpg
(CLICK TO ZOOM)

Each of the screws had to go through a makeover in the drillpress. Using a file, I trimmed them down to make them flush with the rest of the drive case. They were also shortened to the right size.
http://i9.photobucket.com/albums/a10...Hype/024as.jpg
(CLICK TO ZOOM)

Here they are all done. The original screws are the ones in the front. The surface of the modded screws doesn't look that rough in reality. It is probably because this is such a macro shot and the screws are M2 and M3.
http://i9.photobucket.com/albums/a10...oHype/025s.jpg
(CLICK TO ZOOM)

Before and After shot of the trimmed down M2 screws..
http://i9.photobucket.com/albums/a10...oHype/026s.jpg
(CLICK TO ZOOM)

Painted with matt black spray paint.
http://i9.photobucket.com/albums/a10...oHype/027s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/028s.jpg
(CLICK TO ZOOM)

Backside of the top with all the M2 nuts in place.
http://i9.photobucket.com/albums/a10...oHype/029s.jpg
(CLICK TO ZOOM)

Plexi being drilled.
http://i9.photobucket.com/albums/a10...oHype/030s.jpg
(CLICK TO ZOOM)

Some of the holes (the big ones) are not drilled all the way through. This is because they will prevent the bolts from falling in to the drive if they were to come loose but still make room for the M2 bolts when the top and plexi is mounted together.
http://i9.photobucket.com/albums/a10...oHype/031s.jpg
(CLICK TO ZOOM)

And here is the top and window mounted together. Here it's easier to see that some of the holes are not drilled all the way through.
http://i9.photobucket.com/albums/a10...oHype/032s.jpg
(CLICK TO ZOOM)

Hope you like it.


/Gnu

I'm looking at those side reservoirs, round window and three round analog gauges (if i'm not mistaken, and those are really some buttons or miniwindows) on front .. you could have gone steampunk way ..
BTW, speaking of analog gauges. What/which you plan to use there?

I'm liking what I'm seeing! sub'd :up:

Oh man, this is going to be wild!! nice tool choice too :up:

looking nice already and you've barely started, can tell this will be a nice project as im already seeing great attention to detail

keep it up :up:
sub'd

Quote:

---

Originally Posted by churchy

I'm looking at those side reservoirs, round window and three round analog gauges (if i'm not mistaken, and those are really some buttons or miniwindows) on front .. you could have gone steampunk way ..
BTW, speaking of analog gauges. What/which you plan to use there?

---

Your.. spot on. I guess you could kind of call it steampunk without the old copper look. At the moment I got the analog gauges from coolemsater musketer II. (Left - right channel and Hd activity) However im currently searching for some nice analog temp gauges about the same size( 3 - 5cm). Anyone know a place I could get some from?

Quote:

---

Originally Posted by callen_1

Oh man, this is going to be wild!! nice tool choice too :uo:

---

Quote:

---

Originally Posted by erikmorgan

I'm liking what I'm seeing! sub'd :up:

---

Quote:

---

Originally Posted by h20xide

looking nice already and you've barely started, can tell this will be a nice project as im already seeing great attention to detail

keep it up :up:
sub'd

---

Thanks a lot.. hope you'll like the rest aswell

We would say a machine as in Jules Verne's novel. I am ready for the odyssey, and I do not leave the screen. Your engineering workshop is already an introduction in the dream.

Hey,

This is an exciting introduction to your build, and fantastic work so far. I don't have the patience or tools to craft things by hand! I am really interested in how you came about acquiring the anologue gauges, I have always prefered these over LCD gauges and would love to integrate them into my case.

Cheers!

Quote:

---

Originally Posted by manu_D

We would say a machine as in Jules Verne's novel. I am ready for the odyssey, and I do not leave the screen. Your engineering workshop is already an introduction in the dream.

---

wow..thx for your first post and the nice comments. Stay tuned and, I'll do my best to make this "novel" readable aswell :)

Quote:

---

Originally Posted by Mudgey

Hey,

This is an exciting introduction to your build, and fantastic work so far. I don't have the patience or tools to craft things by hand! I am really interested in how you came about acquiring the anologue gauges, I have always prefered these over LCD gauges and would love to integrate them into my case.

Cheers!

---

Thanks..I love the analouge way aswell. The gauges that will be on the front of this build are from a coolermaster muskeeteer II. There will be some other aswell, but I havn't aquired those yet.



Ok
Time for an update of the DVD progress. This update is about the center ring that will hide the magnetic holder of the disk drive that is needed. It will also contain the Activity LED of the DVD drive. This is also the first real part created by the lathe. Since I yet have to by some aluminium material I had to use what whas laying around.

In this case. It was an old heatsink
http://i9.photobucket.com/albums/a10...toHype/34s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/33s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/35s.jpg
(CLICK TO ZOOM)

Starting to take shpe.
http://i9.photobucket.com/albums/a10...toHype/36s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...toHype/37s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...toHype/38s.jpg
(CLICK TO ZOOM)

Finished product.
http://i9.photobucket.com/albums/a10...toHype/39s.jpg
(CLICK TO ZOOM)

Milled two slots for the LEDs. These slots will not be visible and therefore I didn't put too much effort in the finish, as you can see. Also M3 holes are drilled and taped for mounting
http://i9.photobucket.com/albums/a10...toHype/40s.jpg
(CLICK TO ZOOM)

The middle disk.
http://i9.photobucket.com/albums/a10...toHype/48s.jpg
(CLICK TO ZOOM)

This is the acrylic LED ring to distribute the light. Some of the parts look rough but this part won't be vissible.
http://i9.photobucket.com/albums/a10...oHype/41as.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/42s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...toHype/43s.jpg
(CLICK TO ZOOM)

All parts in there orders. The "wires" are the two red LEDs that will fit in the acrylic ring.
http://i9.photobucket.com/albums/a10...toHype/41s.jpg
(CLICK TO ZOOM)

Here you can see the LEDs mounted in the two slots with some hot glue. The wires are along the sides of the outer aluminium ring.
http://i9.photobucket.com/albums/a10...toHype/45s.jpg
(CLICK TO ZOOM)

This is a piece of difuser plastic and black paper added to help even out the light from the LEDs and make the background colour black when the LEDs are turned of.
http://i9.photobucket.com/albums/a10...toHype/46s.jpg
(CLICK TO ZOOM)

Finished LED ring
http://i9.photobucket.com/albums/a10...toHype/47s.jpg
(CLICK TO ZOOM)

This is the magnetic ring that will be placed on the inside of the plexi window and backside of the LED ring.
http://i9.photobucket.com/albums/a10...toHype/44s.jpg
(CLICK TO ZOOM)

more to come

these designs remind me of Bioshock :up:

Quote:

---

Originally Posted by Serpentarius

these designs remind me of Bioshock :up:

---

Without the rust and alga I hope :)

i love my job, but guys you rock at what you do, and it makes me feel jealous from time to time (talkin' to you The_Gnu and callen_1 ;) )
maybe some day i'll have the tools and the skill to do things like that!?
with all i have in mind, there's a lotta nice rig comin' up :D (maybe)

Looking good :up:

Quote:

---

Originally Posted by josk1

i love my job, but guys you rock at what you do, and it makes me feel jealous from time to time (talkin' to you The_Gnu and callen_1 ;) )
maybe some day i'll have the tools and the skill to do things like that!?
with all i have in mind, there's a lotta nice rig comin' up :D (maybe)

---

Thanks for the nice comments..I bet you already do doc, ones the will is there there is nothing to stop you. Im actually surprised by how fast its' possible to learn to use tools. There have been many times that I have feel satisfied with a part just to want to remake it a bit later because I know I have learned the tools much better and could do better. Im a bit afraid I will want to remake the case once its done :S. The skills will come with the patience.

Quote:

---

Originally Posted by D1RtY AssASS1n

Looking good :up:

---

Thanks :)

The dvd mod is looking great, man! I can't wait to see what other crazy stuff you do with your tools!

BTW that marker sketch of the case front looks awesome, you get any of that inspiration from Chip Foose perhaps? :p:

Cool

Quote:

---

Originally Posted by callen_1

The dvd mod is looking great, man! I can't wait to see what other crazy stuff you do with your tools!

BTW that marker sketch of the case front looks awesome, you get any of that inspiration from Chip Foose perhaps? :p:

---

Thanks, man. Chip foose.. hm.. nah. Not on this one even thou he creates masterpieces. Did the marker sketch during a class in industrial design. Been doing some car sketches aswell but those arn't even good enough to wipe foose ass.

Quote:

---

Originally Posted by Alexxx650

Cool

---

thanks :)

Almost forgot, a mini-update. This is the internal LEDs that is supposed to light up the interior of the drive. The LEDs are 10mm 800 000 mcd white leads and puts out quite a lot of light. Not the optimal lightsource since I will use a red window that block a lot of the light. Bt these where the ones laying around at the moment. I might change them later if I feel the need.

I trimmed them down in the mill to be able to fit them on the inside.

http://i9.photobucket.com/albums/a10...toHype/49s.jpg

http://i9.photobucket.com/albums/a10...toHype/51s.jpg

This is the wiring taking power from the backside of the sata-power connector. Not vissible from the front.
http://i9.photobucket.com/albums/a10...toHype/50s.jpg

Let there be light
http://i9.photobucket.com/albums/a10...toHype/52s.jpg

excellent! when you start a build with a lathe and mill you know its gonna get good! i really like the led ring idea and cant wait to see what else you have up your sleeve. +1 for leaving some surprises into the build... its way more interesting that way

Quote:

---

Originally Posted by alphadog009

excellent! when you start a build with a lathe and mill you know its gonna get good! i really like the led ring idea and cant wait to see what else you have up your sleeve. +1 for leaving some surprises into the build... its way more interesting that way

---

Yeah a lathe and mill is a greate addition to the workshop. The possibilities are almost endless of what you can make compared to standard hand tools. Takes some practice and skill though.


It's about time to finish this DVD drive so I can continue with the rest of the case.

Here is the LED ring again if you forgotten about it.
http://i9.photobucket.com/albums/a10...toHype/47s.jpg
(CLICK TO ZOOM)

It is mounted to the outside of the drive window with the magnetic disc holder on the inside. All the taped holes are lined up and screwed together in place using three hex screws.
http://i9.photobucket.com/albums/a10...toHype/53s.jpg
(CLICK TO ZOOM)

The wire for the LED ring is feed along a cut channel in the plastic on the internal case (red circle) and feed through to the other side of the case where it is soldered to the original LED connections.
http://i9.photobucket.com/albums/a10...toHype/62s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...toHype/54s.jpg
(CLICK TO ZOOM)

The whole case is assembled and the dvd drive is finaly done.
http://i9.photobucket.com/albums/a10...toHype/55s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/56s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/57s.jpg
(CLICK TO ZOOM)

Yay it works...
http://i9.photobucket.com/albums/a10...toHype/58s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/59s.jpg
(CLICK TO ZOOM)

Doing a testspinn with a disk.. and it works fine.
http://i9.photobucket.com/albums/a10...toHype/60s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/61s.jpg
(CLICK TO ZOOM)

As you can see the red plexi blocks out some of the light from the White led's, but that was expected. These photos where taken in bright daylight with sun shining in to the room. Therefore it was hard to get a fair picture of the light. The LED ring light is much more evenly lit in reality. Next time I'm at the workshop I will try to get a couple of nightshots to show the lighting better..

There you have it, the result of way to much time spent on a DVD drive. But anyway I'm satisfied with the result and I hope you like it.

Time for the rest of the case..

Nice work man.

Quote:

---

Originally Posted by Rumpus01

Nice work man.

---

Thanks..

Time for some nightshots
It was really hard to capture the true effect of the led light. The real color is too red for the camera to pic up and it gets a more orange color. This is really anoying Because the light is a nice deep red in reality. Untill I get hold of a better camera (tried 2 already) these pics will have to do.

Drive bay open...
http://i9.photobucket.com/albums/a10...toHype/63s.jpg
(CLICK TO ZOOM)

..and closed, with the activity LED ring flashing.
http://i9.photobucket.com/albums/a10...toHype/64s.jpg
(CLICK TO ZOOM)

Time to show some progress of the chassi work. Won't say much exept that I know that some of the bits and pieces could probably have been made in a much more effective way. When creating this case I have realised that using 90 degre L profiles can sometimes result in some complications e.g in the corners. Next time I vill most likely use solid square rods to save some time and headache.

Anyway here are the pics..

Some alu L bar reshaping in the mill..
http://i9.photobucket.com/albums/a10...toHype/65s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/66s.jpg
(CLICK TO ZOOM)

When trying to pop rivet the parts together I realized there was a slight broblem. Couldn't get in to the base with the plier...
http://i9.photobucket.com/albums/a10...toHype/67s.jpg
(CLICK TO ZOOM)

I had to use the lathe to create a small extender out of steel.. If you create something like this you will have to make shure it is not too long since then the plier won't get a good grip of the rivet. This is about as long as my plier can handle.

http://i9.photobucket.com/albums/a10...toHype/68s.jpg
(CLICK TO ZOOM)

And it works like a charm and I have been using it on almost all rivets since most of them are in cramped places.

http://i9.photobucket.com/albums/a10...toHype/69s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/70s.jpg
(CLICK TO ZOOM)

Here is the internal bottom side plate and its mounting brackets. One of them is black because it was part of a previous solution that once it was painted, turned out not to work. Don't worry, the rest of the case parts will allso be painted and anodized black once they are all done.
http://i9.photobucket.com/albums/a10...toHype/71s.jpg
(CLICK TO ZOOM)

This is part of the PSU holder riveted in place...
http://i9.photobucket.com/albums/a10...toHype/72s.jpg
(CLICK TO ZOOM)

..and here is the other part of the psu holder mounted in the chassi.
http://i9.photobucket.com/albums/a10...toHype/73s.jpg
(CLICK TO ZOOM)

Bottom plate brackets mounted in the chassi..
http://i9.photobucket.com/albums/a10...toHype/74s.jpg
(CLICK TO ZOOM)

..and here the bottom plate has been added.
http://i9.photobucket.com/albums/a10...toHype/75s.jpg
(CLICK TO ZOOM)

The bottom plate will be mounted using M3 nutts. That means the 1,5mm thin L brackets that will hold the plate needs to bee threaded. And since I often screw up those threads, because I can't hold the thread tap in a 90degree angle, I did this little tool. I used my drillpress to drill a 90degree hole, the same size as the tap, in a spare peace of aluminium
http://i9.photobucket.com/albums/a10...toHype/76s.jpg
(CLICK TO ZOOM)

Now the thread tap is always 90degree to the hole and the threads are perfectly straight. Very usefull for thin materials where you only have one try..
http://i9.photobucket.com/albums/a10...toHype/77s.jpg
(CLICK TO ZOOM)

PSU backplate being fabricated the good old style..
http://i9.photobucket.com/albums/a10...toHype/78s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...toHype/79s.jpg
(CLICK TO ZOOM)

Riveted in place..
http://i9.photobucket.com/albums/a10...toHype/80s.jpg
(CLICK TO ZOOM)

Time for a test fit of the PSU.. it's a 580w Hiper-R for those wondering.
http://i9.photobucket.com/albums/a10...toHype/81s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/82s.jpg
(CLICK TO ZOOM)

And here it is from the back. The Fan guard is Removed as you can see but will be added later along with the mounting holes for the PSU
http://i9.photobucket.com/albums/a10...toHype/83s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...toHype/84s.jpg
(CLICK TO ZOOM)

Hope you like it.
All comments and criticism are more than welcome.[/QUOTE]

Btw.. It seems like I can't edit the Thread title that is displayed in the worklog section. The title is changed in the thread but not when viewed from the "outside" keeps saying "23- may" or is that just for mee?.

Any ideas on how to solve this?

looks good! i like the backplate for the bottom part but was wondering how you were gonna hide the cables cuz i see no holes through the plate but im probably being an idiot and missing something.... or you probably just have a better idea.

Quote:

---

Originally Posted by The_Gnu

Btw.. It seems like I can't edit the Thread title that is displayed in the worklog section. The title is changed in the thread but not when viewed from the "outside" keeps saying "23- may" or is that just for mee?.

Any ideas on how to solve this?

---

still says 23- may here too mate

No clue

But this build is certainly coming together very nicely

Quote:

---

Originally Posted by alphadog009

looks good! i like the backplate for the bottom part but was wondering how you were gonna hide the cables cuz i see no holes through the plate but im probably being an idiot and missing something.... or you probably just have a better idea.

---

thanks.. na your not an idiot, it's just me that havn't realy decided where to place the holes yet. There will be holes somewhere for shure. At the moment im thinking of routing the cables down through the bottom of the chassi and through one of those alu profiles. Hard to describe but it will come clear eventually.

Quote:

---

Originally Posted by h20xide

still says 23- may here too mate

No clue

But this build is certainly coming together very nicely

---

Thanks mate :up:

Looks like this could be stunning! keep it up! more updates!

Quote:

---

Originally Posted by imersa

Looks like this could be stunning! keep it up! more updates!

---

thanks:up:

*EDIT: oops.. managed to mix the pictures with the last update, so here are the real pictures

it is time to improve the rigidity of the case. Especially the part where the DVD-drive and the harddrives + harddriveblocks will be mounted. This is mainly becasue I reallised that there will be some serious weight and stress on some of the parts and I want to make shure that it alls stays stable

Finally, there is some milling.
But first I need some material. This is the two aluminium squareblocks I purchased for this build. The dimentions are 20x200x1000mm and 10x200x1000mm and almost all of it will be used in this build.
http://i9.photobucket.com/albums/a10...toHype/85s.jpg
(CLICK TO ZOOM)
http://i9.photobucket.com/albums/a10...toHype/86s.jpg
(CLICK TO ZOOM)

Some of the 10mm alu was cut..
http://i9.photobucket.com/albums/a10...toHype/87s.jpg
(CLICK TO ZOOM)

Clamped in the vice and the milling could begin.
http://i9.photobucket.com/albums/a10...toHype/88s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/89s.jpg
(CLICK TO ZOOM)

First milling session is done.
http://i9.photobucket.com/albums/a10...toHype/90s.jpg
(CLICK TO ZOOM)

Test fitting the support brackets...
http://i9.photobucket.com/albums/a10...toHype/96s.jpg
(CLICK TO ZOOM)

..and realised that I need some room for some connections.
Wha that board's for?.. well you'll have to wait and see if you can't figure it out by your self..;)

http://i9.photobucket.com/albums/a10...toHype/91s.jpg
(CLICK TO ZOOM)

The groove is taking shape.
http://i9.photobucket.com/albums/a10...toHype/92s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...toHype/93s.jpg
(CLICK TO ZOOM)

Drilled some holes on the other support brackets as well and some adjustments with the mill
http://i9.photobucket.com/albums/a10...toHype/94s.jpg
(CLICK TO ZOOM)

Now there is enough room for the connections..
http://i9.photobucket.com/albums/a10...toHype/95s.jpg
(CLICK TO ZOOM)


Rivet in place from the backside
http://i9.photobucket.com/albums/a10...toHype/97s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...toHype/98s.jpg
(CLICK TO ZOOM)

This is how I cut the pannels. Using a jigsaw annd an alu ruller.
http://i9.photobucket.com/albums/a10...toHype/99s.jpg
(CLICK TO ZOOM)

As I predicted, there was some nasty gap between the pannel and the motheroard tray (to the right in the picture). Even though it probably won't be vissible once the Motherboard is mounted, I can't stand the knowledge of it being there.
http://i9.photobucket.com/albums/a10...oHype/100s.jpg
(CLICK TO ZOOM)

Fabricated a small part from an L-alu part using the mill. I thought for shure it would bend in the middle but I managed to pull it of. The reason it is black is because I't was intended for another use and since the whole case will be black, it won't matter.
http://i9.photobucket.com/albums/a10...oHype/101s.jpg
(CLICK TO ZOOM)

This is how it will be mounted..with rivets.
http://i9.photobucket.com/albums/a10...oHype/102s.jpg
(CLICK TO ZOOM)

Test fitting the panel
http://i9.photobucket.com/albums/a10...oHype/103s.jpg
(CLICK TO ZOOM)

now thats better..
http://i9.photobucket.com/albums/a10...oHype/104s.jpg
Drilled some holes and did some taping and here the plate is testfitted using m3 hex-bolts. Those hex-bolts stand out cuite a lot and they are only there temporarely. Will change them to some flat head screws.
http://i9.photobucket.com/albums/a10...oHype/105s.jpg
(CLICK TO ZOOM)

there you go.

i smell a mdpc in the works...

More brilliant work! Are those mills relatively easy to use?? it looks like you can do so much cool stuff with them!!

The fix for the gap in the mobo tray turned out fantastic too :up:

Quote:

---

Originally Posted by geoffsthaboss

i smell a mdpc in the works...

---

Thanks mate :)

Quote:

---

Originally Posted by callen_1

More brilliant work! Are those mills relatively easy to use?? it looks like you can do so much cool stuff with them!!

The fix for the gap in the mobo tray turned out fantastic too :up:

---

Thanks, Yeah these mills are easy to use. The precission is very great and your fingers are kept safe ;). There is also the possibility to mod most mills to your own desires, like DIY digital read outs. Only bad thing about these mills that exept the cost for the mill itself, you need a lot of tools and acessories to be able to do a large variety of stuff. What you can do and how precise it is, is often limited by the acessories. Another drawback with my mill is the belt drive, it takes a lot of time to change the speed. a mill with gearbox is better but often more expensive.

God luck

okay, sorry for my abcense but I have to say I don't feel too enthusiastic to keep posting updates while the title of my log still says 23 may. I've tried to contact moderators but with no luck. Anyone know of a moderator that might be worth sending a PM?


Well heres the next update.

This is the part Im about to fabricate next, it is the top (and bottom) of the case as you probably already figured out.
http://i9.photobucket.com/albums/a10...oHype/106s.jpg
(CLICK TO ZOOM)

This is how the finished parts hopefully will look. It's a quite advanced shape, atleast I think so. Since I don't have acess to a CNC, the rounded surfaces will be a pain in the ass to fabricate
http://i9.photobucket.com/albums/a10...oHype/107s.jpg
(CLICK TO ZOOM)

This is the profile of the bars and the support for them. The bottom of the bars and the support might look a little bit unnecessarily complex. The reason for this is that there will be alumium mesh added between the rods and this will probably make it a little bit more easy to install. There is also the airflow in mind. The support will probably still see some modifications to ease the fabrication, if you know of any, please let me know since I'm still learning.
http://i9.photobucket.com/albums/a10...oHype/108s.jpg
(CLICK TO ZOOM)

This is how I intendt on creating the curve. Milling the parts in a stair patern and then even out the curved surface by hand with a file. This is the only solution I have to the problem at the moment, please let me know if you got a better one that will save me some elbow grease.
I was thinking of fabricating my own cutter with the desired radius but I would need to fabricate 3 different ones and also a tool to create them.
http://i9.photobucket.com/albums/a10...oHype/109s.jpg
(CLICK TO ZOOM)

Picked up some aluminium square rods last week. The thickness is 20mm and it was delivered in 6 X 1m lengts.
http://i9.photobucket.com/albums/a10...oHype/110s.jpg
(CLICK TO ZOOM)

The first thing to do was to cut them all down to 50cm lengts.
http://i9.photobucket.com/albums/a10...oHype/111s.jpg
(CLICK TO ZOOM)

At this point I'm starting to realise how much this case will weigh...a lot
http://i9.photobucket.com/albums/a10...oHype/112s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/113s.jpg
(CLICK TO ZOOM)

Since the rods are 20mm square, I need to mill them down 2mm since I want them to be 18 mm. I could have bought 18mm square rods from the beginning but since (half) of these rods will be on the top of the case and very vissible, I wan't them to be perfect. There is almost always some dents or large scratches from the metal supplier and therefore I prefer to have some excess material.
Btw this is one of the mills at school that I finally have acess to, not my own. This one is much larger and there is a lot of nice tools. Like this facemill.
http://i9.photobucket.com/albums/a10...oHype/114s.jpg
(CLICK TO ZOOM)

I also discovered a second vice wich helped me speed up the facemilling process a lot, since there is a total of 24 sides that need to be treated.
http://i9.photobucket.com/albums/a10...oHype/115s.jpg
(CLICK TO ZOOM)

I ran out of time and had to stop after half of the pieces where done. This is what I got so far.
http://i9.photobucket.com/albums/a10...oHype/116s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/117s.jpg
(CLICK TO ZOOM)

See ya

Hello
I have had some alignment problems with the mill im currently using at school and therefore the toprods have ended up taking longer to fabricate than estimated. For that reason I have also started the work on some other parts of the project to speed up the process a bit. This is the work currently done on the top rods

all 12 rods and 24 sides are facemilled and ready for the rough milling.

http://i9.photobucket.com/albums/a10...Hype/118_s.jpg
(CLICK TO ZOOM)



http://i9.photobucket.com/albums/a10...Hype/119_s.jpg
(CLICK TO ZOOM)

Here is the first rod taking shape. Each step has a different depth to create the a rough shape of the desired radius.

http://i9.photobucket.com/albums/a10...Hype/120_s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...Hype/121_s.jpg
(CLICK TO ZOOM)



http://i9.photobucket.com/albums/a10...Hype/122_s.jpg
(CLICK TO ZOOM)

This is suposed to bee one of the underside of the rods. Managed to screw it upp a bit because the previously mentioned alignment problems with the vices. Think I managed to save it though.
http://i9.photobucket.com/albums/a10...Hype/123_s.jpg
(CLICK TO ZOOM)

The work on the toprods are on hold untill I manage to solve the problems with the vices.
Therefore I started working on the HD-blocks that are a lot less problematic to fabricate.

This is the plan for the HD blocks. Two solid Alu blocks that will cool up to three hard drives. The water will enter the top block and continue on to the second block through a single tube and then exit the second block through 6 separate tubes.

http://i9.photobucket.com/albums/a10...oHype/hd1s.jpg
(CLICK TO ZOOM)

Layout of the top block. The middle "plate" is supposed to be a plexi window to add to the geekyness. There will also be a thin sheat of rubber to (hopefully) make it leak proof.

http://i9.photobucket.com/albums/a10...oHype/hd2s.jpg
(CLICK TO ZOOM)

Sideview of the top block, here you can see the chanel structure

http://i9.photobucket.com/albums/a10...oHype/hd3s.jpg
(CLICK TO ZOOM)

Bottom block, with chanel structure.

http://i9.photobucket.com/albums/a10...oHype/hd4s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/hd5s.jpg
(CLICK TO ZOOM)


Time for fabrication.
First of I need some thick pieces of alu. These are 160x20mm and cut with an angle grinder

http://i9.photobucket.com/albums/a10...Hype/124_s.jpg
(CLICK TO ZOOM)




http://i9.photobucket.com/albums/a10...Hype/125_s.jpg
(CLICK TO ZOOM)

Using an endmill to trimm the edges and make it the right dimentions.

http://i9.photobucket.com/albums/a10...Hype/126_s.jpg
(CLICK TO ZOOM)



http://i9.photobucket.com/albums/a10...Hype/127_s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...Hype/128_s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...Hype/129_s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...Hype/130_s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...Hype/131_s.jpg
(CLICK TO ZOOM)

So... my work with the HD blocks continues
I discovered that the two alupieces I've previously cut were not totaly flat. They had a slight curve on them and therefore needed some treatment. The curve was from the manufacturing process so if you plan on buying anything like this, it's a good thing not to buy the exact dimension since this seems to be quite common. I used the 4-jaw chuck, on the lathe wich alows me to attach non cirkular workpieces.


http://i9.photobucket.com/albums/a10...oHype/132s.jpg
(CLICK TO ZOOM)

Have to make shure to keep those fingers out of the way.

http://i9.photobucket.com/albums/a10...oHype/133s.jpg
(CLICK TO ZOOM)

Here you can se the curve of the pieces. The center part is beeing romeved first while the edges are left untouched and this is because the curve.

http://i9.photobucket.com/albums/a10...oHype/134s.jpg
(CLICK TO ZOOM)

After some passes the piece is nice and flat. Flipped it over an did the same on the other side.

http://i9.photobucket.com/albums/a10...oHype/135s.jpg
(CLICK TO ZOOM)

To bad they will probably not stay this shiny during the rest of the working. Well...will probably have to redo the surface once finished.
http://i9.photobucket.com/albums/a10...oHype/136s.jpg
(CLICK TO ZOOM)



http://i9.photobucket.com/albums/a10...oHype/137s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/138s.jpg
(CLICK TO ZOOM)

Here I'm starting to drill the channels in one of the blocks. They will be threaded with M8 threads later and therefore I used a 7mm drill. 6,8 is the optimal drill for this thread but I didn't have that one so this will have to do. The depth of the holes are 60mm.
http://i9.photobucket.com/albums/a10...oHype/139s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/140s.jpg
(CLICK TO ZOOM)


Flipped the pieces over and started to drill the holes for the HD mounting. I used a 4mm drill to drill all the way through.

http://i9.photobucket.com/albums/a10...oHype/141s.jpg
(CLICK TO ZOOM)

For those of you thinking of doing somethings similar, the long distance between the holes are 101,6 mm which is standard for 3,5" HDD.

http://i9.photobucket.com/albums/a10...oHype/142s.jpg
(CLICK TO ZOOM)

Here I use a 8,5 mm drill to make room for the head of the HD mounting screws. These holes are not drilled all the way through.

http://i9.photobucket.com/albums/a10...oHype/143s.jpg
(CLICK TO ZOOM)



http://i9.photobucket.com/albums/a10...oHype/144s.jpg
(CLICK TO ZOOM)



http://i9.photobucket.com/albums/a10...oHype/145s.jpg
(CLICK TO ZOOM)




http://i9.photobucket.com/albums/a10...oHype/146s.jpg
(CLICK TO ZOOM)

Time to start threading with the M8 tap. The alu piece with a hole in it is the guid tool I made to make shure the thread starts taping at a 90degree angle.

http://i9.photobucket.com/albums/a10...oHype/147s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/148s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/149s.jpg
(CLICK TO ZOOM)

Also did some edge chamfering of the holes to give it a nicer look. Here you can se that the large hole is not all the way through since it leaves 2mm in the bottom to make the screws pop out enough on the mounting side.

http://i9.photobucket.com/albums/a10...oHype/150s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/151s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/152s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/153s.jpg
(CLICK TO ZOOM)

There is still the largest intake hole, some mounting holes and surface treating left to do but you get the idea.

I wana move into your house! :)

WOW, amazing work here! Keep it up, I am looking forward to the updates.

Now here is something that merits a WOW! Thanks for the update!

OCM :up:

holy cow, awesome!

Quote:

---

Originally Posted by eclypse

I wana move into your house! :)

---

Haha no you don't. I live in a small apartment far away from the tools unfortunately. Some work you see is done at my mums house (my tools though) and the larger machines you might see in some updates are from my schools workshop.

Quote:

---

Originally Posted by Fyrelith

WOW, amazing work here! Keep it up, I am looking forward to the updates.

---

Quote:

---

Originally Posted by OC Maximus

Now here is something that merits a WOW! Thanks for the update!

OCM :up:

---

Quote:

---

Originally Posted by Jokester_wild

holy cow, awesome!

---

Thanks a lot guys.. Hope you'll like the rest aswell :P

Wowsers! Looking good!!

Very clean cuts you got there.

Quote:

---

Originally Posted by Zeus

Wowsers! Looking good!!

---

Thanks:up:

Quote:

---

Originally Posted by ScottALot

Very clean cuts you got there.

---

Thanks..I try my best. I Meassure 2-3 times before cutting to to avoid misshaps, but that still doesn't prevent some misstakes from happening :S

Insane.:eek: Subscribed.

Quote:

---

Originally Posted by The_Gnu

Thanks..I try my best. I Meassure 2-3 times before cutting to to avoid misshaps, but that still doesn't prevent some misstakes from happening :S

---

Measure twice, cut once!

Quote:

---

Originally Posted by Lagaaja

Insane.:eek: Subscribed.

---

Nice.. thanks

Quote:

---

Originally Posted by ScottALot

Measure twice, cut once!

---

Ehm..yeah I wish twice was enough :)

Looking nice, keep up the good work

Quote:

---

Originally Posted by rocket733

Looking nice, keep up the good work

---

Thanks. I'll try :)



With one of the Hd-blocks almost done, its time to start the work on the next one. This one will be a little bit more of a challenge than the previous one since it will require a lid with a leakproof sealing. The plan is to seal it with a rubber gasket but I've been told that an O-ring seal is better. However using an o-ring on this block would require a total makeover of the block since ther isn't enough room (as you'll see in the pics later). I decided to give the rubber gasket a shot and see if it's possible. If its not.. well I'll have to redo it.

First of I cutt a slot with a 6mm endmill. This is to make things a little bit easier for the final 8mm mill. The slot was made in several steps to get to the desired depth of 10mm.

http://i9.photobucket.com/albums/a10...oHype/154s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/155s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/156s.jpg
(CLICK TO ZOOM)


Here I've milled the slot again with a 8mm end mill.

http://i9.photobucket.com/albums/a10...oHype/157s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/158s.jpg
(CLICK TO ZOOM)

When milling slots that is as wide as the cutter, one of the sides tend to get a nice finish, while the other side gets pretty rough. This is because of the milling direction. To get a nice finish on both sides, I milled it over once again while taking a very small cut about 0,05mm of the rough edge. This left the nice side untouched and smoothed out the rough side. If you look closely you can se the fine line between the rough and smooth surface right on the left of the mill.

http://i9.photobucket.com/albums/a10...oHype/159s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/160s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/161s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/162s.jpg
(CLICK TO ZOOM)

Drilling 2,5mm holes that for the M3 threads

http://i9.photobucket.com/albums/a10...oHype/163s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/164s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/165s.jpg
(CLICK TO ZOOM)

Again.. my little taping tool to keep the holes at a 90deg angle.

http://i9.photobucket.com/albums/a10...oHype/166s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/167s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/168s.jpg
(CLICK TO ZOOM)

All M3 threads done. Here you can se that there is almost no space left to fit an O-ring as I mentioned eralier. Lets just hope I can get it sealed enough with the rubber gasket. I'm afraid it might be a bit tricky...but hey. it's worth a shot.

http://i9.photobucket.com/albums/a10...oHype/169s.jpg
(CLICK TO ZOOM)

Here I'm drilling the internal channels for the whater to pass through.

http://i9.photobucket.com/albums/a10...oHype/170s.jpg
(CLICK TO ZOOM)

This shot you better enjoy because I was doing the drilling while taking a picture and it almost messed up the whole part. The drill managed to slip a little bit in the beginning and created some ugly marks by the top of the hole as you can se in the last photo of this post.. I was seriously thinking of redoing the whole part because of that, but I swallowed my pride and perfectionism and decided it will have to do.

http://i9.photobucket.com/albums/a10...oHype/171s.jpg
(CLICK TO ZOOM)

Drilling some mounting holes, similar to the ones on the previous block.

http://i9.photobucket.com/albums/a10...oHype/172s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/173s.jpg
(CLICK TO ZOOM)

And there you have it... the two blocks together. I still got the water in/out channels left to drill on both of them.

http://i9.photobucket.com/albums/a10...oHype/174s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/175s.jpg
(CLICK TO ZOOM)

Here you can see the drillslip mark I was talking about. Third hole from the top on the left piece....Gaah it hurts to know that it's there.
http://i9.photobucket.com/albums/a10...oHype/176s.jpg
(CLICK TO ZOOM)

I have been trying to fabricate the top for the HD block. The hardest part was, as expected, to create the rubber gasket and make it able to provide a leakproof seal. I first tried by cutting a gasket from a sheat of rubber but soon abandoned that idea to try the luck with silicone. The silicone was also hard to use since I would need to be able to remove the silicone once set, and that wasn't easy without destroying the silicone. This ended up with a leaking seal and I decided to give another shot at cutting a rubber gasket. The second time it turned out much better and this is the method I'm sticking with at the moment. I still have to hard test it for leeks while applying real pressure since I've only been testing it with the pressure my lungs are able to produce :).

Anyway... Here are the pictures of the last parts for the HD blocks in the making.
Sorry for the crapy quality of the first 4 pictures. I forgot my real camera at home and had to use the "light identifier" also known as "camera" on my nokia 5310.

http://i9.photobucket.com/albums/a10...oHype/192s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/193s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/194s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/195s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/196s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/197s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/202s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/203s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/204s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/198s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/199s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/200s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/201s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/205s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/211s.jpg
(CLICK TO ZOOM)




I couldn't keep myself from modding the screws just a tiny bit. Gave them a treatment in the lathe to make them a littlebit smaller and give them a more edgy look.
http://i9.photobucket.com/albums/a10...oHype/206s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/207s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/208s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/209s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/210s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/212s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/213s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/214s.jpg
(CLICK TO ZOOM)




Had to do some test fitting with some old harddrives. Fits like a glove but dang this thing turned out heavy :)

http://i9.photobucket.com/albums/a10...oHype/215s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/216s.jpg
(CLICK TO ZOOM)

There you have it... the HD blocks are done, (apart from the finishing surface treatment later on). Now it's time to work on the rest of the build.

/GNU

go ahead and watercool the psu while you're at it!

Quote:

---

Originally Posted by ScottALot

go ahead and watercool the psu while you're at it!

---

Actually, I did some tests regarding that yesterday. Either heatpipe or watercooling was my thoughts but it turns out that one of the heatsinks of the PSU is live (240V). Therefore I think I'll leave the modding of the PSU. But maybe I'll give it a try if I can figure something out or find a PSU without live heatsinks.

wow, does that give enough cooling to hard drives? looks sick anyway

Quote:

---

Originally Posted by The_Gnu

Actually, I did some tests regarding that yesterday. Either heatpipe or watercooling was my thoughts but it turns out that one of the heatsinks of the PSU is live (240V). Therefore I think I'll leave the modding of the PSU. But maybe I'll give it a try if I can figure something out or find a PSU without live heatsinks.

---

:P http://www.koolance.com/water-coolin...product_id=911

Another crazy mdf :up:. Holly:cow:, Impresive looking biuld

Quote:

---

Originally Posted by aka_GK

wow, does that give enough cooling to hard drives? looks sick anyway

---

It depends of what you mean with "enough". I guess it'll atleast be better than nothing.. From what Ive heard Hard drives are designed to dissipate the heat to the sides, not shure how true that statement is but there are similar coolers on the market so I guess the concept works...But we'll see

Quote:

---

Originally Posted by ScottALot

:P http://www.koolance.com/water-coolin...product_id=911

---

wow..The price is just as over the top as the product itself, but atleast it's quiet :P Thanks for the link

Quote:

---

Originally Posted by Awers

Another crazy mdf :up:. Holly:cow:, Impresive looking biuld

---

Thanks a lot :)

awesome and impressive build

makes me want to have all of those tools :)

Quote:

---

Originally Posted by hillywav

awesome and impressive build

makes me want to have all of those tools :)

---

Thanks a lot, Well regarding the tools... once you started collecting them they stack pretty fast :)


After the Hd-blocks were done, I could countinue with the case itself. These parts are for supporting the top and bottom part of the case...and to get that round shape. It'l probably make more sense in the next uppdate when there will be some more parts added.

Some 10mm Alu cut to a basic shape.
http://i9.photobucket.com/albums/a10...oHype/217s.jpg
(CLICK TO ZOOM)

A rotary table is used to get a curved shape. a
http://i9.photobucket.com/albums/a10...oHype/218s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/219s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/220s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/221s.jpg
(CLICK TO ZOOM)

Hate those nasty edges but, it's good theyr pretty easy to remove.
http://i9.photobucket.com/albums/a10...oHype/222s.jpg
(CLICK TO ZOOM)

I was needed to upgrade my tools with a set of 3mm needle files.
http://i9.photobucket.com/albums/a10...oHype/223s.jpg
(CLICK TO ZOOM)

The parts could not be completed in the mill alone and therfore I had to do the last shaping by hand, these red parts had to be removed since i needed a straight edge without a radius.
http://i9.photobucket.com/albums/a10...oHype/224s.jpg
(CLICK TO ZOOM)

I used a regular file to get that basic shape...
http://i9.photobucket.com/albums/a10...oHype/225s.jpg
(CLICK TO ZOOM)

then there were a copule of houres for me and the needle files to get to know each other... One almost done, 7 to go :S
http://i9.photobucket.com/albums/a10...oHype/226s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/227s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/228s.jpg
(CLICK TO ZOOM)

Countersunk the holes with an endmill to make the screwheads fit.
http://i9.photobucket.com/albums/a10...oHype/229s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/230s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/231s.jpg
(CLICK TO ZOOM)

After some hours of filing and wetsanding all 8 sides where done. Was really hard not to mess up that radius but I think it turned out ok.
http://i9.photobucket.com/albums/a10...oHype/232s.jpg



http://i9.photobucket.com/albums/a10...oHype/233s.jpg



http://i9.photobucket.com/albums/a10...oHype/234s.jpg

Thats it if for this day.
Feel free to post any comments, questions or criticism

/GNU
(CLICK TO ZOOM)

The part of the build im currently in right now is the top and bottom of the case. This is one really timeconsuming and hard part of the build. Also most of the parts look the same which might result in less pics.

Maybe you remember these 12 alubars, They need to be milled down in a step patern following a radius to make the sanding easier. Since I don't have acess to a cnc, I'll have to do it by hand :(. It might sound simple to just mill them down in straight steps and I thought that too. Well it turned out not to be that easy when you have 2 different vices. Pain in the ass to align them.
http://i9.photobucket.com/albums/a10...Hype/234as.jpg
(CLICK TO ZOOM)

First steps milling down to the right height
http://i9.photobucket.com/albums/a10...oHype/235s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/236s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/237s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/238s.jpg
(CLICK TO ZOOM)

Then it's time to mill the steps..
http://i9.photobucket.com/albums/a10...oHype/239s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/240s.jpg
(CLICK TO ZOOM)

First part done..
http://i9.photobucket.com/albums/a10...oHype/241s.jpg
(CLICK TO ZOOM)

Second one in the making, slightly different.
http://i9.photobucket.com/albums/a10...oHype/242s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/243s.jpg
(CLICK TO ZOOM)

Here I am testfitting the parts and realized that those steps are probably to large. Will take a long time to sand them down by hand and I risk loosing the shape. Will have to make smaller steps..
http://i9.photobucket.com/albums/a10...oHype/244s.jpg
(CLICK TO ZOOM)

..like these ones.
http://i9.photobucket.com/albums/a10...oHype/245s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/246s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/247s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/248s.jpg
(CLICK TO ZOOM)

Now thats better. But the part in the middle is 1mm to high And I will need to mill that of the bottom, because this hurts my eyez.
http://i9.photobucket.com/albums/a10...oHype/249s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/250s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/251s.jpg
(CLICK TO ZOOM)

Here you can get a glimpse of what the finished top will look like. The bars need to be cut to the right lenght, the one that's shorter is already cut...duh
http://i9.photobucket.com/albums/a10...oHype/252s.jpg
(CLICK TO ZOOM)

Now I'll just have to do this all over again for the bottom pieces.:sigh: I so hope the finished result will meet my expectations.
See ya.

/GNU

So much work done yet so much still to come.. Hope you can make it all the way trough!

Great start! Can't wait to see it finished! :up:

Quote:

---

Originally Posted by Lagaaja

So much work done yet so much still to come.. Hope you can make it all the way trough!

---

Yeah there is quite a lot left, but I try to tell myself that the hardest parts are almost done. It will be done, that I can ashure you but I reckon that all the waterblocks will cause som headache. But it'll be fun atleast

Quote:

---

Originally Posted by zalbard

Great start! Can't wait to see it finished! :up:

---

Thanks.. :up:

I'm speechless... :O. This is definitely my all-time favorite here. Gotta say that I'm really jealous of you having all the equipment and patience for that... And also gotta hate you for making such an awesome case that makes me wanna cry when I look at mine xD.

Quote:

---

Originally Posted by Elpy

I'm speechless... :O. This is definitely my all-time favorite here. Gotta say that I'm really jealous of you having all the equipment and patience for that... And also gotta hate you for making such an awesome case that makes me wanna cry when I look at mine xD.

---

Thanks for the very nice comment. Patience is my middle name and the tools are just a bonus :) I would say the quality of a build is determined by the experience , the more you build the better it gets. Trust me you would cry if you saw my first case aswell. It was made out of a kitchen kabinet and som plexi, so uggly I didn't even bother to finish it. But I learnt something :)

Here we go again.
I managed to get to the workshop and finish the milling of the last rods for the top and bottom of the case. Since there are 12 in total, these milling pictures might seem somewhat familiar to the previous pictures buut anyway, here they are.

http://i9.photobucket.com/albums/a10...oHype/253s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/254s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/255s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/256s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/257s.jpg
(CLICK TO ZOOM)


Yay.. almost done with the last one
http://i9.photobucket.com/albums/a10...oHype/258s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/259s.jpg
(CLICK TO ZOOM)



http://i9.photobucket.com/albums/a10...oHype/260s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/261s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/262s.jpg
(CLICK TO ZOOM)

The shapemilling of all the pieces is finally done. Next up is cutting, drilling and taping holes for them to be mounted. And of course there is the sanding. Hope you liked this mini update.

See ya[/QUOTE]

The work continues.

Next up was the mountingholes on the underside of the rods. Drilled and taped with M4.
http://i9.photobucket.com/albums/a10...oHype/263s.jpg
(CLICK TO ZOOM)

This is how i solved the issue with the mounting holes on the corner pieces ending up on an edge making it impossible to drill with a normal drill. Had to countersunk the hole (left)with a normal endmill before I could use the drill.
http://i9.photobucket.com/albums/a10...oHype/264s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/265s.jpg
(CLICK TO ZOOM)

I had to moddify the screws a bit since they were a little bit to long and this was faster than hunting for new ones.
http://i9.photobucket.com/albums/a10...oHype/266s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/267s.jpg
(CLICK TO ZOOM)

TADA
http://i9.photobucket.com/albums/a10...oHype/268s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/269s.jpg
(CLICK TO ZOOM)



http://i9.photobucket.com/albums/a10...oHype/270s.jpg
(CLICK TO ZOOM)


http://i9.photobucket.com/albums/a10...oHype/271s.jpg
(CLICK TO ZOOM)

Next up is the sanding proceedure. To have some guidens while sanding I painted the whole piece with a black permanent marker pen. The desired radius is the smallest one, the one that is created by the inner/lowest corners in each step. When sanding, the black marker paint will stay in these corners and create black lines that get smaller and smaller the further you sand. When the lines dissapear, you have the correct radius. It's pretty hard to see from this angle with all the reflection but all the rods are pinted black
http://i9.photobucket.com/albums/a10...oHype/272s.jpg
(CLICK TO ZOOM)

http://i9.photobucket.com/albums/a10...oHype/273s.jpg
(CLICK TO ZOOM)

This is just a test sanding and I started sanding using a vibrating mous or whatever you wanna call them. The process is kind of slow and I suppose a file would have been a greate beginning, but I didn't have one at the moment. Will try that next time.
http://i9.photobucket.com/albums/a10...oHype/274s.jpg
(CLICK TO ZOOM)
'
Here you can see the black lines are getting thinner and thinner the closer you get to the finished shape.
http://i9.photobucket.com/albums/a10...oHype/275s.jpg
(CLICK TO ZOOM)

This last photo shows why I have waited to cut the rods to the exact length. You always get some kind of chamfer on the edges when sanding. By cutting the exact length after the sanding I will have straight edges aswell.
http://i9.photobucket.com/albums/a10...oHype/276s.jpg
(CLICK TO ZOOM)

Still a lot of sanding to do but, I guess you get the idea.
Thanks for watching :thumb:

This looks like one to watch.
I really love the style of the concept renders (I'm a fan of this kind of look, which I would describe as a cross between steampunk and Half Life 2)
Hope things progress smoothly.

Quote:

---

Originally Posted by Aphex_Tom_9

This looks like one to watch.
I really love the style of the concept renders (I'm a fan of this kind of look, which I would describe as a cross between steampunk and Half Life 2)
Hope things progress smoothly.

---

Thanks, HL2 and steampunk is actually something thats been in my mind during the project. The first plans for this project was only to do one big external steampunk watercooling unit. Then it evolved into a flat case supposed to lay down but ended as a normal tower style case with some inspiration by HL2

What happened to this awesome build?

UPDATES!!! UPDATES!!! UPDATES!!!

Quote:

---

Originally Posted by Obsidian Rift

What happened to this awesome build?

UPDATES!!! UPDATES!!! UPDATES!!!

---

Thanks for missing me. This project is not dead I can asure you. However it is in a phase where I'm redesigning some of the parts to make it easier to fabricate and to make it look better. So at the moment the building process is only virtual. There is also other projects that have been occupying my time, but those are soon done and then this work will continue as usuall. Sorry for this but I think it will be woth it in the end.