Scratch Project: Veritas

THE FOLLOWING EVENTS TOOK PLACE IN A REAL LONG TIME, BETWEEN 01:00 AND 240:000 HOURS, BUT MORE TOWARD 240.

http://img203.imageshack.us/img203/1284/87501511.jpg


So after Eldritch I swore I would never do another mod again--this coming from trying to get my crazy loop working inside 7 inches of cubic space in a parking garage in Seattle with a pair of chopsticks with 60 hours of sleep for the week and five hours before the BYOC at PAX.

I'm pretty sure there are a few run-on sentences in there...anywho...it wasn't long before the itch crept back on me, and I started sinking into deep planning sessions for my next build. For hours at a time I would slip into my lab, planning, thinking, and mostly playing the SCII beta while generating piece by piece the perfect mod:
http://img841.imageshack.us/img841/4996/pylons.jpg
SHUT UP, I KNOW ALREADY


Until it hit me--PDX was three weeks away and all I had for plans was part of a napkin with "veritas" scribbled in red ink...or ketchup...but probably red ink:
http://img690.imageshack.us/img690/6545/nappy.jpg
I can't afford a notebook. Don't judge me. :(

Since I was this far along, there was absolutely no reason to panic.
Que panic.
http://www.bytelove.com/images/uploa...nic-button.jpg
I actually own one of these and mash it frequently.

PANIC HAS BEEN QUEUED.

So I got to planning. I spent the first week planning:
http://img508.imageshack.us/img508/8549/planningl.jpg

NO, not that kind, the REAL kind of planning. I wanted a mini-itx system that wasted no cubic space, looked interesting from all sides, and made people wonder (by looking at the outside) about the orientation. I finally came up with these:

http://img695.imageshack.us/img695/1231/1sketchup.jpg
http://img411.imageshack.us/img411/9870/2sidepanel.jpg
http://img130.imageshack.us/img130/1884/3reservoir.jpg
http://img811.imageshack.us/img811/7...nalrenders.jpg


While I could easily spend the next few pages going over the pieces that went into the design, that would be boring, and also I seem to have misplaced the pictures associated with them. Instead I have put together a one-half second time lapse of the process:


one-hal

OK done, wasn't that great?

Moving on. I knew that I was not about to build another system on the floor in my room, so I got to work setting up shop. Literally:
http://img843.imageshack.us/img843/2243/imag0002o.jpg
http://img695.imageshack.us/img695/1517/imag0009td.jpg
http://img714.imageshack.us/img714/5965/imag0010xl.jpg
http://img294.imageshack.us/img294/7236/imag0011j.jpg
http://img694.imageshack.us/img694/1674/imag0012xn.jpg
http://img340.imageshack.us/img340/8243/imag0017r.jpg
http://img718.imageshack.us/img718/5177/imag0018h.jpg
http://img203.imageshack.us/img203/9257/imag0023jn.jpg
http://img24.imageshack.us/img24/4622/imag0024st.jpg


Yes, it happened just like that--all in a few blurry pictures. But seriously I was surprised how quick I threw the bench together--and even more surprised it didn't fall apart, then burn down. In that order. :up:

With the workbench out of the way I was free to begin my craft....

...but I will continue my thread tomorrow...:yepp: Also lemme know if the pictures are too big, and I will re size them.

oo goody, another NFC masterpiece

she looks devilishly top heavy though

Rule #1 of putting together a workshop: Never, never, NEVER let a cactaur near the workbench.

(Looking forward to seeing how this one takes shape ;D)

Quote:

---

Originally Posted by anachlores

she looks devilishly top heavy though

---

Just how I like 'em :up:

Quote:

---

Originally Posted by Geezer

Rule #1 of putting together a workshop: Never, never, NEVER let a cactaur near the workbench.

---

Too late. Anymore rules I can break? Seriously I'm going for a record on this on. =D

Mkay, so where were we. Ah yes, the PSU. So I knew I needed a custom solution for this system--something with enough power for the 9800GT and the 860 but much smaller than a micro PSU. I decided I could hack up micro-atx PSU and do some soldering and call it a day. Boy was I wrong...

See, the first lesson I learned is if your design isn't on paper, then it's going to cost you. Sure, I had some good ideas along the way that weren't planned, but they weren't structural...:shakes:

Let me guide you on my journey of five PSUs, as I delved into aluminum for my first time, and had to fall on my face and do a few barrel rolls.

First PSU:
http://img121.imageshack.us/img121/3459/1pylon.jpg

http://img709.imageshack.us/img709/4489/1fsgroup.jpg
I've used these before in the past, and Silverstone started using them last year confirming that they probably don't blow (I will eat these words later, I promise you;))
http://img820.imageshack.us/img820/7086/2open.jpg
PSU warranties are for sissies.
http://img405.imageshack.us/img405/7962/3moreopen.jpg
http://img805.imageshack.us/img805/7...ofnoreturn.jpg
You can fake a sticker, but this is harder to explain to the RMA department. =)
http://img828.imageshack.us/img828/8247/5snip.jpg
http://img138.imageshack.us/img138/2723/6coolmesh.jpg
I bought a 12"x12" sheet of this stuff. It was $35 and I thought it would be enough for a single PSU. Hah.
http://img33.imageshack.us/img33/6791/7tapedoff.jpg
I should have done this throughout the mod, it would have saved on sanding.
http://img693.imageshack.us/img693/9...ugandstuff.jpg
I will use these later in a different part of the case.
http://img541.imageshack.us/img541/6...alscissors.jpg
Just like preschool!
http://img411.imageshack.us/img411/9...ockbending.jpg
Wood, not just for bonfires anymore!
http://img121.imageshack.us/img121/2...ampbending.jpg
Ok so the wood didn't work that great...but maybe drop forged steel...
http://img148.imageshack.us/img148/7523/12rough.jpg
I wouldn't lick it, just sayin'
http://img189.imageshack.us/img189/936/13file.jpg
...but maybe I would after some filing =D
http://img839.imageshack.us/img839/9164/14morefile.jpg
This is going to be a trend, I can feel it...


Are the pictures too big? I figure most of us are running 1920x1080+ these days.

Doing them in 800x600 from now on...

http://img202.imageshack.us/img202/4738/15cuttabs.jpg
makin the tabs...
http://img809.imageshack.us/img809/9987/16dremel.jpg
good old fashioned dremeling
http://img33.imageshack.us/img33/4228/17sideplate.jpg
sideplate is cut, and I hate it.
http://img52.imageshack.us/img52/464...pare2drill.jpg
going to drill out the tabs for screws anyways...
http://img807.imageshack.us/img807/7...ginmalaser.jpg
at least this is awesome
http://img94.imageshack.us/img94/586...ountersink.jpg
This teaches me I should glue the plate to wood or something before drilling :yepp:
http://img541.imageshack.us/img541/6...functional.jpg
At least it works...
http://img826.imageshack.us/img826/6...tplacement.jpg
my choice of firewater
http://img8.imageshack.us/img8/314/23base.jpg
I was planning on using an acrylic base (for electrical resistance) and top that would make contact with the board. Then I was going to light the insides with LEDs, and do a frosted design on the top. I wish this worked out...
http://img535.imageshack.us/img535/5...andingbase.jpg
Getting the edges sanded down
http://img844.imageshack.us/img844/9...ingspacers.jpg
At first I decided to make my own spacers...
http://img132.imageshack.us/img132/9...ngheatsink.jpg
I realized I needed to shorten the heatsink (as soon as I opened the PSU)
http://img801.imageshack.us/img801/5229/27fatality.jpg
FATALITY
http://img18.imageshack.us/img18/4480/28hpacleaning.jpg
Set my air compressor to 200PSI and nuked the cutting particles...almost took off a few capacitors too. ><
http://img830.imageshack.us/img830/6738/29base.jpg
As you can see I gave up on my own spacers and used some acrylic cubes I had...
http://img641.imageshack.us/img641/5...rtingposts.jpg
I needed to shorten the posts, which did not happen easily...

http://img202.imageshack.us/img202/2...morefiling.jpg
I might need to put warning notes before filing pictures...
http://img825.imageshack.us/img825/4...forbending.jpg
I read somewhere online this would help the aluminum make a nice neat bend.
http://img706.imageshack.us/img706/1327/33nicebend.jpg]
The internet is full of truth!
http://img689.imageshack.us/img689/632/34somesides.jpg
Here is one of the sides, all bent in shape.
http://img16.imageshack.us/img16/236...avysanding.jpg
I was young, and reckless! Also I didn't realize how fine the sandpaper should be for that brushed look! This paper made it waaaay too rough.
http://img834.imageshack.us/img834/2...vybrushing.jpg
So I did the only thing I knew--busted out the wire brush to make it rougher!
http://img811.imageshack.us/img811/3327/37result.jpg
meh
http://img266.imageshack.us/img266/9200/38lpieces.jpg
MEH
http://img13.imageshack.us/img13/184/39cuttingvents.jpg
Wasn't about to give up...still needed to cut vents for the air to flow right...
http://img823.imageshack.us/img823/7...orecutting.jpg
Some more cutting...
http://img707.imageshack.us/img707/3...ingcorners.jpg
Using Harbor Freight hole saw...
http://img411.imageshack.us/img411/3...afterdrill.jpg
http://img265.imageshack.us/img265/1984/43filing.jpg
After I filed it...
http://img265.imageshack.us/img265/9489/44result.jpg
Not so bad, if you like CRAP:p:

I hated that attempt. So it was on to #2:

SECOND PSU:
http://img299.imageshack.us/img299/503/2pylon.jpg

http://img340.imageshack.us/img340/4221/1cutandbent.jpg
http://img809.imageshack.us/img809/2...gestrimmed.jpg
http://img826.imageshack.us/img826/8...gforfiling.jpg
http://img192.imageshack.us/img192/1723/4roughedges.jpg
Preparing for filing, oh, and I should warn you...
http://img337.imageshack.us/img337/8726/filing.jpg
Don't say I didn't warn you =D
http://img101.imageshack.us/img101/7...oltagesink.jpg
I made a quick return to this sink, and finished it up.
http://img132.imageshack.us/img132/1...ratedpiece.jpg
Then I started filing this perforated piece...
http://img695.imageshack.us/img695/1...rnersround.jpg
Filing it round....
http://img245.imageshack.us/img245/9...gesprecise.jpg
I wanted this design to fit so perfect that the top would be secure without any screws, so it required...more filing...
http://img440.imageshack.us/img440/8...gforfinish.jpg
The thing I love second to filing, sanding!
http://img5.imageshack.us/img5/3323/10roughfinish.jpg
The finish turned out rough, but I was confident I could polish it.
http://img14.imageshack.us/img14/1338/11closeup.jpg
Not bad for 200grit =P
http://img525.imageshack.us/img525/5...nishonperf.jpg
Yeah, again, before I discovered that the grit numbers went above 600 :rofl:
http://img832.imageshack.us/img832/2...tsformbpos.jpg
I had the right kind of machine screws, just not the right length...
http://img412.imageshack.us/img412/7...ostspacers.jpg
Fan vibration dampeners made for some nice spacers...
http://img199.imageshack.us/img199/6...irstpostin.jpg
Shes's in!

http://img97.imageshack.us/img97/113...ountinghol.jpg
I wanted to mount the board right to the PSU chassis...
http://img256.imageshack.us/img256/9...apping35mm.jpg
So after drilling I tapped it with a 3.5m tap
http://img651.imageshack.us/img651/7...wassembled.jpg
It's starting to look like something...
http://img137.imageshack.us/img137/4...leforwires.jpg
I needed to file the hole I cut earlier for the GPU and HDD wires...
http://img6.imageshack.us/img6/9277/...geforwires.jpg
I also needed to make a cut for the 24 pin...
http://img529.imageshack.us/img529/8...filingedge.jpg
:rolleyes:
http://img46.imageshack.us/img46/920...bergrommet.jpg
Some of Bill Owen's molding...moulding...rubber edge stuff...:p:
http://img441.imageshack.us/img441/9710/23preview.jpg
Eh
http://img185.imageshack.us/img185/6...otherangle.jpg
Eh..m..hmmm
http://img707.imageshack.us/img707/457/25snugfit.jpg
It's snug though...
http://img840.imageshack.us/img840/5...bepolished.jpg
Needs polish...
http://img828.imageshack.us/img828/9...rentneeded.jpg
It is tight enough so screws aren't needed, like the origional plan.
http://img201.imageshack.us/img201/6200/27interior.jpg
You guys can see the gap:
http://img836.imageshack.us/img836/3858/28space.jpg
Plenty of clearance.
http://img822.imageshack.us/img822/8...cctfriedit.jpg
AND THEN OCCT FRIED IT. :mad: It popped so bad that it left scorch-marks on the aluminum. I was pretty frustrated, but then again that is why I stressed it. I knew I could do better than that attempt anyways...

Attempts 3, 4 and 5 tomorrow night. Sleepy time now. =D

You might be able to get a small metal bending brake to make the 90 degree angles a little easier. I was looking at one for shaping the back panel for my case that would have been good for making fairly straightforward bends like the ones you were making in the attempts you showed and it was about $30. (This guy. )

For light duty work if you're doing enough mods/full case designs involving aluminum or mild steel, it may be worth looking into. (For more complicated stuff you could look into something like this, but it's a bit spendy for occasional modding.)

sounds lieka n ordeal. I want to see what happens next to PSU 3 ^_^

Quote:

---

Originally Posted by Geezer

You might be able to get a small metal bending brake to make the 90 degree angles a little easier...

---

Thanks for the links :up: Oh how I wish I bought one of those before this project, but I was foolish and ended up making my own (after all the sheet metal bending was done :down: ) because I couldn't bear the thought of ever working with aluminum again--even if I was doomed to. :)

http://img341.imageshack.us/img341/660/rotozip.jpg
http://img834.imageshack.us/img834/2...etalbender.jpg

Quote:

---

Originally Posted by anachlores

sounds lieka n ordeal. I want to see what happens next to PSU 3 ^_^

---

Then I shall continue!

(and when are you going to finish your project?--I'm excited to see how it turns out! :D)

PSU THREE:
http://img338.imageshack.us/img338/6213/3pylon.jpg

Since I destroyed the other PSU spectacularly with a pop that I heard through three walls, it was time for another--the Diablo 380!:
http://img408.imageshack.us/img408/275/1diablo380w.jpg
Specs:
http://img838.imageshack.us/img838/1512/2specs.jpg
Yummy, another PSU's warranty gone:
http://img412.imageshack.us/img412/3...ngwarranty.jpg
Whoa, a removable fan pin! Classy!
http://img217.imageshack.us/img217/6...emovablefa.jpg
This interior will make it difficult to route wires, luckily the heatsinks are facing the right direction (sarcasm):
http://img64.imageshack.us/img64/666...ghinterior.jpg
I like the color of this female end better, so I'll use it: :p:
http://img153.imageshack.us/img153/681/7acremoved.jpg
I decided it would be easiest to use a jigsaw to cut the shape out, so I drilled a hole for the blade:
http://img69.imageshack.us/img69/296...eforjigsaw.jpg
I ruined the piece with the jigsaw, so I busted out the rotozip instead:
http://img827.imageshack.us/img827/4...djustuseda.jpg
hehe, easy as cutting out a shape with a Rotozip:
http://img413.imageshack.us/img413/963/9zipped.jpg
Everyone's favorite part, filing:
http://img192.imageshack.us/img192/5...ilingedges.jpg
This is looking hopeless...
http://img713.imageshack.us/img713/2...filingtodo.jpg
I had an idea on how to cheat and get out of filing:
http://img189.imageshack.us/img189/4...tchandbend.jpg
Whoa, being lazy paid off:
http://img802.imageshack.us/img802/9...muchfaster.jpg
done filing: (I love saying those two words together :) )
http://img44.imageshack.us/img44/3971/14edgesfiled.jpg
Making marks for round 2 of cuts--by the way, for future reference, this should have been done AFTER the bending!!!:
http://img204.imageshack.us/img204/3...secondcuts.jpg
Piece subtracted:
http://img17.imageshack.us/img17/1823/16cutmade.jpg
Ok, so I am missing about a gig of pictures on this project. My camera has been sleeping around with various hard drives, but I cant find a certain folder anywhere. This makes me a sad face, because some of the really cool parts of this project (a whiles away yet) are missing. I'm wondering if they are buried on my sim card somewhere and if I should use recovery software to find them...
http://img690.imageshack.us/img690/3226/dramaicon.png
Don't get me wrong, I still have many, many pictures of me filing things to make up a decent worklog. =) I'll just have to narrate where some work occured and hand you a picture of the finished project, and an Ice Cream Cone*.

Ok so here is what it looked like all filed and sanded:
http://img838.imageshack.us/img838/4...thensanded.jpg
These pictures speak for themselves, I don't know what they say, but here they are:
http://img20.imageshack.us/img20/7504/18finish.jpg
http://img809.imageshack.us/img809/3...sandedperf.jpg
http://img810.imageshack.us/img810/5824/20preview.jpg
Ok, go go gadget bender:
http://img186.imageshack.us/img186/21/21bending.jpg
http://img34.imageshack.us/img34/8346/22morebending.jpg
http://img837.imageshack.us/img837/7...ofpictures.jpg

Theeennnnn I ruined it. I made a bad bend and hammering it out resulted in marking the piece bad and I couldn't sand them out. I decided, conveniently, that I hated the design and I could do better. Notice a trend?

=P


*You will not get an actual Ice Cream Cone. Sorry.

PSU 4
http://img412.imageshack.us/img412/9267/4pylon.jpg

This is one of the sections I am missing pictures of. Luckily, it just looked like failure (if interested in seeing what failure looks like, please scroll up).

Holy cow, 4 down.... We need to write a song!

As for my project, it's almost done actually. I have been a bit lazy with the pictures but within the next few weeks, the case will be done. I'm not sure how long the actual transfer of components will take though. I'm going on vacation next week so it cuts into work time T_T

PSU 5
http://img714.imageshack.us/img714/1166/5pylon.jpg

Whoot! I stayed with this design because I was running out of time and was sick of rebuilding PSUs. Although not as neat as I wanted, installed in the case it looked great. Anywho.


These are the 3.5m anodized screws I used in this PSU attempt, and throughout the case:
http://img541.imageshack.us/img541/1...ewsarrived.jpg
I was sick of thin aluminum, so I grabbed a chunk of 5mm thick stuff and made a base:
http://img31.imageshack.us/img31/9471/2cutbase.jpg
There was a bunch of filing to do, so I did it:
http://img85.imageshack.us/img85/415...dbaseflush.jpg
http://img841.imageshack.us/img841/2290/4morefiling.jpg
http://img266.imageshack.us/img266/9...morefiling.jpg
Whoot, flush pieces, that almost never happens:
http://img833.imageshack.us/img833/1...swereflush.jpg
http://img842.imageshack.us/img842/1...omefinally.jpg
I drilled the edges for the pins I was going to use to connect them:
http://img827.imageshack.us/img827/4...edforbolts.jpg
In with the pins, just like voodoo...oh snap now I have David Bowie stuck in my head. =(
http://img256.imageshack.us/img256/5541/9pinsrather.jpg
WILL IT FIT? OH THE SUSPENSE:
http://img571.imageshack.us/img571/3...entoftruth.jpg
http://img819.imageshack.us/img819/8...rmeasuring.jpg
:D
http://img204.imageshack.us/img204/8...holeforcab.jpg
I didn't have the right bit for this job, so it took some work:
http://img186.imageshack.us/img186/2659/13morelube.jpg
This hole, btw, was for the cables which are routed on the sides:
http://img19.imageshack.us/img19/675...lingcircle.jpg
Seriously, you have to glue thin material down to wood to cut it right with the jigsaw. Unfortunately I did not have wood, so I used a combination of pure ivory and sea-turtle shells (not pictured):
http://img7.imageshack.us/img7/9053/...withjigsaw.jpg
eah, I used the rotozip in the end. =P
http://img194.imageshack.us/img194/6...sejigagain.jpg
:rolleyes:
http://img818.imageshack.us/img818/2518/17filing.jpg
Using the dremel to make a notch for the bend:
http://img571.imageshack.us/img571/7...ingforbend.jpg
Closeup of the rounded edge, to aid in the bend:
http://img841.imageshack.us/img841/6...forsmoothe.jpg
I almost broke my drill press cutting these holes with cheap hole-saw pieces from Harbor Freight. As I would learn later, do not skimp on good cutting bits. =(
http://img826.imageshack.us/img826/2...ressonthes.jpg
Filefilefilefilefile
http://img651.imageshack.us/img651/6...ingcircles.jpg
All the pieces to cut!
http://img842.imageshack.us/img842/7008/22piecescut.jpg
I had pictures of the painful wet-sanding process, but they are gone. BTW, I jumped from 600 to 1000 grit paper, and as such it shows (looks bad). I couldn't find 800 or 900 around town, so in the future I have to order some online. For later pieces I had 800 and 900 and I was able to achieve a mirror finish on parts.
http://img709.imageshack.us/img709/9147/23wetsanded.jpg
http://img706.imageshack.us/img706/9...hinypieces.jpg
Oops, I missed an edge...back to the 200grit:
http://img51.imageshack.us/img51/6749/25missededge.jpg
There we go:
http://img22.imageshack.us/img22/4291/26gotit.jpg
http://img830.imageshack.us/img830/4678/27shiny.jpg
http://img21.imageshack.us/img21/1944/28pcieandsata.jpg
http://img535.imageshack.us/img535/7...etouchedup.jpg
I decided it would be clever to use a straight-edge to assist with the bend for this material, as I shaved off quite a bit in the sanding process:
http://img8.imageshack.us/img8/3293/...htedgeforb.jpg
Applying heat, cause it looks awesome:
http://img37.imageshack.us/img37/2253/31heatforbend.jpg
I wanted the edges to be PERFECT, thus, the filing:
http://img715.imageshack.us/img715/6...dgeperfect.jpg
And it fits great:
http://img293.imageshack.us/img293/2...perfectfit.jpg
Let's glue!
http://img443.imageshack.us/img443/2...paringpins.jpg
I needed to drill and tap the front panel for the screws:
http://img197.imageshack.us/img197/7...gesforpins.jpg
Here it is before I got the angle sorted out:
http://img841.imageshack.us/img841/8...rstscrewin.jpg
WHOOT! Something that doesn't suck. Now it is time to sleeve!
http://img14.imageshack.us/img14/484...metosleeve.jpg

BTW, in case you guys were wondering, I drilled multiple holes to make the cables look spread out--and I used black and pink for the different holes to give it a cool look as the randomness went into a pattern.

So the sleeving process was pretty complicated as the wires had to be routed and in some case re-soldered back in place, and the heatsinks had to be cut and drilled so the wires would work. All the wires were custom cut to length, and measured so that when they made the bend, it looked like a neat loop.

You can't see this in the picture, but stick around for the end and you will see the effect:
http://img190.imageshack.us/img190/5162/psuol.jpg

The non-sleeved wires got sleeved eventually--and power wired for the female AC plug were routed under the motherboard.

Here is a screenshot of it on my "test bench" ...lol

http://img46.imageshack.us/img46/1319/img4203t.jpg

I want to thank Nil for his amazing sleeving and even more awesome tool! I had been using the Frozen CPU tool in the past, and while that tool was very good compared to the others out there, Nil's blows it away. The secret is in the filed tips which let you slide it right in--no hassle. Thanks Nil! :up:

WE WANT MORE!!!!!!!

and did you put a acrylic cover over the metal of the PSU? I cant tell if it is acrylic or the bare metal with the lighting in that picture. But I love the etc/design. Excellent work, as usual.

Sorry to take so long, I didn't think anyone was really interested because this is a really BORING worklog. If I continue it I really have to speed things up.

Also, Sapphire asked me to do a build for quakecon, so I was working overtime to get them a rig--now that Quakecon is over I can get back to posting here if you would like. =)

As for the PSU, I take really terrible pictures cause I have a 100 dollar camera and no skills. It is just bare polished aluminum and I used cabinet laminate for the angel:

http://img130.imageshack.us/img130/2850/img4084vi.jpg


What I did is I made a stencil and used an Xacto knife to cut out the angel, then I stuck the angel on the PSU. =)

I am missing ALOT of pictures from this worklog, which is really frustrating me....

Well, even if it is just contact paper, it still looks awesome in that lighting.

keep up the god work and keep posting in this "boring" worklog.

MKAY

So like a hundred pictures later, and all we have is a power supply.
BORING. I wasn't really going to do a worklog for this case as I have some more interesting PCs, but I thought I would have time. W/E I'm pretty deep into this one now, so I will go fast and try to finish it in a few posts. =)

Anywho...

Here we go again:

I had intended from the start to use those cool, anodized, purple, screws (ADJECTIVESPLOSION). With this intent I decided to bend my own L brackets using a clamp and drill press:

http://img696.imageshack.us/img696/5654/img4085s.jpg

Then, after what seemed like hours (because it was), I managed to finish with the top plate the radiator would bolt to using a drill press, jig saw, roto-zip, and dremel. Please thank me for sparing you with about a hundred pages of filing :p: :

http://img138.imageshack.us/img138/581/img4086z.jpg

After attaching two planes together with the screws It became apparent this would be nowhere near sturdy enough to survive the final sanding and polishing I intended to do:

http://img412.imageshack.us/img412/1714/img4088w.jpg

So I switched to rivets, which worked amazingly well. To get the holes lined up to attach the L angle aluminum I used a jig consisting of two $16 dollar drill press vices I found at the Home Depot. This ended up being about $40 dollars less than the pre-made solution Sears tried to sell me, and far more versatile:

http://img706.imageshack.us/img706/6590/img4089w.jpg

The back aluminum plate would screw in no problem to the acrylic after I tapped it, so I wasn't worried about that. The screws would not hold the L angle though, so again, I had to use rivets. The trick here was countersinking the acrylic so I could mount the aluminum back panel flush with it.

First I glued it down with superglue, then clamped it:

http://img838.imageshack.us/img838/9144/img4093t.jpg

Then I drilled out the screw taps, and countersunk the holes for the rivets:

http://img196.imageshack.us/img196/717/img4094b.jpg

Here is what they looked like on the backside:

http://img696.imageshack.us/img696/2962/img4096c.jpg

On the inner side:

http://img130.imageshack.us/img130/8826/img4098b.jpg

Next it was time to make the HDD bracket. I needed something that could hold both the SSDs I was using in a very small space. I have pictures of the prototype I made for this, but not the final version that had cleaner edges (except in the final photoshoot). Keep this in mind for the next couple shots.

First I had to measure the aluminum (EXCITING!):

http://img217.imageshack.us/img217/6638/img4099o.jpg

Then I used my Seagate "paperweight" as a stencil =P:

http://img844.imageshack.us/img844/8265/img4100.jpg

How do you find riveting things to acrylic? I read somewhere that it was a no-no because the pressure on the acrylic would cause it to crack/craze, but obviously your results seem to be the exception to the rule. And are you using cast acrylic or extruded?

Cast--I am pretty sure extruded would explode :p:

Yeah, it was an experiment for me. I tested it out on a few pieces and even the 1/16th didn't crack (though I would NOT anything that thin for structural).

With the 4.7mill thick stuff I used, it worked fantastic and would have no problems recommending it for structural applications.

One word of caution, do NOT use steel rivets--use aluminum. :up:

Beautiful action documentary :D

Quote:

---

Originally Posted by dualbrain

Beautiful action documentary :D

---

Why thank you, Nils!

This one is nowhere near MDPC quality, but it was unique as y'all should see here coming up. My next build (already done) is closer toward your standards =)


Now for the next ACTION PACKED sequence: :cool:

Shiny plate with bend scoring:
http://a.imageshack.us/img841/996/img4101g.jpg

All da markings:
http://a.imageshack.us/img405/6788/img4102ai.jpg

Various cuts and holes made:
http://a.imageshack.us/img580/1221/img4103n.jpg

First bends--again, this piece I ended up throwing away--the piece I ended up keeping was similar in design, just executed better :) :

http://a.imageshack.us/img13/1777/img4104dj.jpg

Here is the test drive, fitted in the first attempt:

http://a.imageshack.us/img338/8484/img4106my.jpg


Mkay that was boring, but more interesting stuff to come in my next post, which I will work on later...

Lovely.

So I am using a friends PC for the weekend, and all he has installed is IE...which logged me out of XS for some weird "security" reason after I clicked my submit post. No biggie, except I had spent an hour working on it as it was the biggest update so far =P I learned my lesson and am using Notepad for the weekend!

I'm not going to spend alot of time redoing this tonight so I'll just talk about one picture, so you guys can LOOK at the picture, and not read anything I type. =)

http://a.imageshack.us/img840/7928/img4109.jpg

So there was about a hundred pictures to get to this point. Since a picture is worth a thousand words, and a thousand times a hundred is probably a billion (I don't understand maths) that means I have alot of words to type. So here goes...

First I had to come up with a design/pattern for the interlocking parts. I did this in photoshop rather quickly. Then I needed to cut the pieces out, so I began to sort through the huge pile of scrap I aquired over the past week due to my poor measurments or lack of talent in cutting. When I had taken inventory, I used the jigsaw and alot of clamps to cut out the rough shapes. Then I did something so stupid that I just have to encourage you all to do...wait...no, the other thing...BEG YOU NOT TO TRY. I removed the shield and fence from my table saw, and using my delicious fingers, guided the pieces and trimmed them just right. I can't stress enough how stupid this is, I only attempted it because I am an angel cyborg with regenerative properties, and I have too many fingers in the first place. Also an extra arm.

After the pieces were cutout I drilled, countersunk, and tapped the holes for the screws, and did so ALL the way through to the acrylic so they would line up correctly. I used clamps to secure the pieces while I did this.

Then after two days of sanding they were shiny.

The hardest part was attaching the side panel to the chassis. I did this just like the last version of the power supply--with pins. I measured very carefully, and by the grace of God the holes ended up matching somehow--then I glued pins on the chassis side, and drilled four more holes for tiny magnets. This way the side panel can be removed and put into place and stay there using the power of magents, which is like any other super power only less awesome.

After I was done with the side panel I am pretty sure I had a beer. Not sure if that is relevant.

More tomorrow. Probably. =)

Also, I don't know if any of you noticed from the above picture, but the sandwitch works like: aluminum--acrylic--aluminum--acrylic---aluminum. The lines of acrylic that go along the borders of the case will be illuminated =)

I can tell there's lots of work going into the case. The last picture you posted almost makes me want to play Tetris.

Almost...

Are you using edge-lit acrylic or just relying on the properties of standard acrylic for the illumination?

OI! NFC if you start loosing fingers now, I wont get aymore all natural, fresh squeezed goodness.
Really shiny pieces though

Quote:

---

Originally Posted by Geezer

I can tell there's lots of work going into the case. The last picture you posted almost makes me want to play Tetris.

Almost...

Are you using edge-lit acrylic or just relying on the properties of standard acrylic for the illumination?

---

The fluorescent acrylic works really well for what you are talking about, but I didn't have any to use for this project so this is standard, clear, cell-cast acrylic.

Quote:

---

Originally Posted by anachlores

OI! NFC if you start loosing fingers now, I wont get aymore all natural, fresh squeezed goodness.
Really shiny pieces though

---

Yes, but if I do lose my fingers I'll be sure to include the pulp =D

Quote:

---

Originally Posted by NFC

Yes, but if I do lose my fingers I'll be sure to include the pulp =D

---

The only thing that makes a custom case better is when it comes with free finger sausage...

Errr...

I meant to do some more updates earlier, but losing my big post to IE made me sad face.

:(


Moving forward onto the last main piece to the chassis frame...

This normally would be the backside of a case, but in this mod it is an invisible piece--there is no backside to my case as any side could be the front. If I follow a pattern I like to make all sides of my mods interesting and unique (also include the angel theme...duh..)

I cut a slab 'o luminum to the appropriate size and measured the hole for the I/O Shield:

http://a.imageshack.us/img685/7186/img4110s.jpg

Cut said hole:

http://a.imageshack.us/img815/5453/img4112.jpg

Drilled holes...IN YOUR MOM. Oh wait no, for the power plug, then I sawed out some of the remaining material:

http://a.imageshack.us/img401/4932/img4114n.jpg

Then I filed it. Surprise surprise:

http://a.imageshack.us/img17/5383/img4116i.jpg
http://a.imageshack.us/img64/8310/img4117j.jpg

Then I test fitted it and secured the L-angle on the opposing frame:

http://a.imageshack.us/img525/3947/img4123e.jpg

(its not done yet--which is why it still looks ugly. Note the notch for the pump cord)

http://a.imageshack.us/img690/6642/img4124z.jpg

I test-fitted the I/O shield and the power plug:

http://a.imageshack.us/img411/7554/img4125e.jpg
http://a.imageshack.us/img821/8980/img4126q.jpg

I was getting tired of filing and decided to sleeve the grounding cable:

http://a.imageshack.us/img265/9350/img4127k.jpg

I fixed some of the areas that needed a heavy filing (everything will be sanded and polished before it is done) and bolted it in place to make sure everything was lining up good:

http://a.imageshack.us/img714/6910/img4128g.jpg

Oh, in the above picture, that short L-angle that is bolted to the piece that hosts the I/O shield will hold several LEDs that will illuminate the side panel.

I had to drill through the acrylic to the backpanel so I could screw them together, and while I was at it I drilled the holes for the motherboard:

http://img130.imageshack.us/i/img4131a.jpg/

http://a.imageshack.us/img130/5316/img4131a.jpg

I tapped the threads for the Lian Li standoffs, but I also superglued them in:

http://a.imageshack.us/img411/8849/img4134uv.jpg

By the way, I highly recommend that control gel from Loctite--it doesn't cloud up as bad as other glues which can really ruin your acrylic. Plus, as it states it is a thick gel which applies very easily with no run.

With the frame assembled (still needs to be sanded and polished) it was time to take a break and move onto something more tedious and frustrating: the reservoir! :rolleyes:

Normally a reservoir holds liquid, and while mine does hold more than normal tubes, its main purpose is for filling and draining the loop. I wasn't sure about the design, but I went with it anyways and it actually worked really great:

http://a.imageshack.us/img693/1884/3reservoir.jpg

Photoshop was exciting and easy, drilling was dull and difficult--also it took about two hours:

http://a.imageshack.us/img822/7008/img4141b.jpg

I used a water/alchohol mix for coolant, and had to go very slow for a centimeter at a time and then stop, clean everything out, then re-align the setup for the next centimeter. It sucked.

One hole down (I will refrain from your mom comments):

http://a.imageshack.us/img818/6974/img4143p.jpg

Two holes ( getting harder....):

http://a.imageshack.us/img175/6536/img4145x.jpg

Three (...can't....stand...it....):

http://a.imageshack.us/img717/9189/img4146r.jpg

For this setup to work I needed to merge the big holes on both ends, which is what I was doing in this picture:

http://img17.imageshack.us/i/img4148tw.jpg/

Then I flame polished the insides of the holes:

http://a.imageshack.us/img823/8930/img4150t.jpg

http://a.imageshack.us/img691/6136/img4156tz.jpg




Ok more later (in a timely fashion) :) Also, I apologize for the dullness of this thread, but I am trying to speed through because I have many more worklogs I need to get up on here and this computer isn't really worth the time.

Nice job drilling the acrylic for the reservoir. That's one of those things that could have gone either very well or very, very badly ;D

Quote:

---

Originally Posted by Geezer

Nice job drilling the acrylic for the reservoir. That's one of those things that could have gone either very well or very, very badly ;D

---

Thank you for your comments, Geezer. It makes this place a 'lil more lively. :)

As the computer nears completion, it gets more interesting. I want to finish the log across two more sessions.

Using a toothbrush and Novus 2 and 3 I polished the inside of the reservoir some more:

http://a.imageshack.us/img835/6761/img4158f.jpg

Back in the house I was leaktesting the hardware...and perhaps testing the UV paint out a little bit too :ROTF:

http://a.imageshack.us/img832/108/img4159iy.jpg
I was a bit disappointed in the paint--I thought it was supposed to be pink UV as the cap was pink (using the clearneon stuff). Instead it was more of a white (though it looks blue in the pictures).

After the frame was completely riveted together it looked terrible and was not flush:

http://a.imageshack.us/img839/2346/img4162v.jpg

Using power tools was not an option, so I did what you might expect:
http://img829.imageshack.us/i/img4163.jpg/

This was the most amount of filing I had to do for the whole project all in one sitting...

http://a.imageshack.us/img829/8695/img4163.jpg


After it was flush and looking presentable I made a new LED holder and riveted it on:

http://a.imageshack.us/img838/4421/img4164x.jpg

This part was more than a bit tricky--drilling the holes for the posts and magnets. I couldn't drill through, obviously, and I needed them to match precisely on the side panel:

http://a.imageshack.us/img801/8471/img4165m.jpg

This is the stage where I actually drilled in the armor plating and countersunk them:

http://a.imageshack.us/img830/1889/img4166y.jpg

Here is what it looked like with the pins and magnets on one side:
http://a.imageshack.us/img826/234/img4167k.jpg

Everything lined up on the first shot, and the side panel came on and off how I planned, which was a blessing and frankly was not expecting. :up:

http://a.imageshack.us/img839/2322/img4168g.jpg

At this point in the worklog I am missing about 1/3 of my overall picture set. This includes alot of my hand etching (which I did with this) and some fabrication. What I was most proud of was my hardcore modification of my tap chuck I bought from Harbor Freight. I found this awesome heavy-duty drill chuck (which you will see in pictures coming up) that was just a TAD bit to small for my BSP19 tap. Using a rotozip and a bench grinder I was able to modify it to accept the tap. I had some sweet pictures of this process with tons of awesome sparks, but I can't find them. >< If I am missing something you are confused about let me know and I will explain it with words.

Here is a picture of me test-fitting the top cover I made. It just had come off the table saw so the edges are still rough and not polished:

http://a.imageshack.us/img835/3674/img4169l.jpg

The victim for the armor plating pieces =)

http://a.imageshack.us/img827/4302/img4170t.jpg

I bent this with my tableclamp:

http://a.imageshack.us/img839/4656/img4171r.jpg

This is a VERY rough cut, but you can see where it is headed before filing and positioning:

http://a.imageshack.us/img834/3313/img4173j.jpg

Here is the etched insert with the two 65x10mm fans. These fans are high pressure high flow and while they aren't quiet, they don't have a annoying whine. These will directly mate with the custom heatsink for the 9800GT:

http://a.imageshack.us/img834/3703/img4174k.jpg

I found out that I needed to extend the power button so it wouldn't interfere with a capacitor on the GPU. I decided to so something that looked interesting and I could illuminate. Here is a picture of it about halfway done:

http://a.imageshack.us/img830/7563/img4175w.jpg

Using these absolutely terrible bi-metal blades from Harbor Frieght I literally ruined my drill press. They vibrated and popped out and misalligned the chuck. I don't know the names of drill press parts, but basically its not even and I can't drill precise holes or use the nice hole saws that arrived in the mail a bit later. =( This is the kinda thing you don't purchase at Harbor Freight and I learned my lesson. :shakes:

http://a.imageshack.us/img830/7729/img4176.jpg

I had to end up drilling lots of small holes and using a hacksaw to cut out the piece. Soooooo much filing was needed to get the hole looking nice:

http://a.imageshack.us/img830/5867/img4177.jpg

For such thin metal, it did file nicely and I got some pretty accurate holes:

http://a.imageshack.us/img833/5184/img4178k.jpg

The other armor pieces I tried every tool I had trying to find the fastest way, which ended up being the roto-zip to score the marks, then a dremel and file for the separation and cleanup.

Back to the "front" -- you can see the finished power button extension and how the insert...um...inserted? :D

http://a.imageshack.us/img836/1457/img4179n.jpg

Two pictures of the front--notice the little plastic piece with the three drill marks? Those will hold the two UV and one red led, which make an awesome hot pink color:

http://a.imageshack.us/img831/4717/img4181g.jpg
http://a.imageshack.us/img830/6656/img4182.jpg

Here is a picture of the armor plating test fitted on the front. They still need to be filed more, and polished:

http://a.imageshack.us/img825/5172/img4183o.jpg

Here is another angle. The fans are coated in the UV paint btw:

http://a.imageshack.us/img828/2681/img4184n.jpg

Here is a picture of the armor plating for the back side scored by the rotozip, ready to be broken apart:

http://a.imageshack.us/img829/8522/img4185w.jpg

Here is a picture of my awesome tap and chuck which I am so very proud of :D (this is a picture of a test fitted nozzle)
http://a.imageshack.us/img842/2752/img4186k.jpg

Next I had to thread the "up" hole with the tubing, and tap the other holes:

http://a.imageshack.us/img837/8663/img4187k.jpg

I didn't have time to hand etch the insert for the backside, so I had it lasered. I didn't end up using it in the case, but here is a picture of it just the same:

http://a.imageshack.us/img843/9638/img4188j.jpg

The top panel was completed and everything was test fitted so I could drill for the last run of light-pipes:

http://a.imageshack.us/img842/184/img4189o.jpg


Ok, more later--which involves the final assembly and the final shots! :p:

I just noticed that I left out two really important pictures up there regarding filing the frame straight so I fixed it...

Shame to hear about the drill press. Try here.

Did you hand etch the light pipes/circuit design?

And i'm growing to love your cyborg angel logo. It looks great on that block.

Quote:

---

Originally Posted by Geezer

Shame to hear about the drill press. Try here.

---

Thanks for the link, I will be sure to shop there to get this thing back in order :up:

Quote:

---

Originally Posted by anachlores

Did you hand etch the light pipes/circuit design?

---

Dremel etcher for the win! I really am P.O. that I am missing so many pictures of the process. It's one of the reasons I'm rushing through this log so I can start on my next....:(

Quote:

---

Originally Posted by anachlores

And i'm growing to love your cyborg angel logo. It looks great on that block.

---

I'm not an artist. I wish I was, though I was happy with how that angel turned out on the block.

Last stretch.


Two fans but only one motherboard header:
http://a.imageshack.us/img826/6052/img4191c.jpg
http://a.imageshack.us/img826/1990/img4192j.jpg
http://a.imageshack.us/img844/682/img4193s.jpg
http://a.imageshack.us/img837/4511/img4196y.jpg

Here is a picture of the "backside", it still has some sticky residue on it from the contact paper stencil I had made, if you can forgive that:

http://a.imageshack.us/img825/2627/img4197.jpg

This is what it looks like in the dark under UV:

http://a.imageshack.us/img839/5348/img4199.jpg

It was supposed to be pink, like the rest of the case theme...but oh well. I know for next time. (Not that I will ever do pink again =P)

I had very little space in the system and nowhere near enough 4 pin connectors on my modded PSU, so I had to wire the fan controller for the deltas directly to the PSU:

http://a.imageshack.us/img801/3685/img4212.jpg
http://a.imageshack.us/img832/3507/img4213g.jpg

since everything was designed to fit to the milimeter (my projects that came after this I planned for some extra slack) I had some trouble getting all the parts in. The sleeving and wires for the PSU were measured and cut in such a way that they would make a nice bend without extra material getting in the way, so the sleeving in this picture looks like it is coming undone a little, but it will all get pushed back in:

http://a.imageshack.us/img801/8741/img4215i.jpg

More fitting parts and making measurements for various braces:
http://a.imageshack.us/img839/7634/img4217d.jpg

Most of the wiring was run in channels under and next to the motherboard:
http://a.imageshack.us/img827/3240/img4220y.jpg
http://a.imageshack.us/img843/5402/img4221xy.jpg

Some of the wires for the fan controller and 12 LEDs in the bottom had to make this ugly cross under the CPU though:
http://a.imageshack.us/img830/1130/img4222d.jpg

Since the reservoir had to fit in the aluminum socket I made and the tubing lengths had to be precise, it was a bit of trouble getting it in:
http://a.imageshack.us/img843/5508/img4224l.jpg

Everything finally made it in. I should mention this assembly took place in the final hours (after being up for 40 hours) before my plane left for Washington. I was feeling a bit rushed at this point. =)

http://a.imageshack.us/img830/3302/img4226j.jpg

The drives were incredibly difficult to get in because of the space constraints. They had to share a 5"x2" space with my LED board, tons of LED wires, and the wiring for the GPU. Yes, the sleeving came undone as I battled them in. Yes, I fixed it after they were in, as you shall see:

http://a.imageshack.us/img839/7641/img4228c.jpg

I needed someplace to run some additional LED wires--this cut was made much earlier of course:
http://a.imageshack.us/img826/1629/img4231k.jpg

SSDs, led board, GPU, and wires all stuffed in the small little space:

http://a.imageshack.us/img842/5756/img4233.jpg

Getting the stupid power switch in was also annoying:

http://a.imageshack.us/img826/9223/img4234t.jpg

It's a blurry picture, but it finally made it in there, LEDs and all:
http://a.imageshack.us/img835/8523/img4239j.jpg

This is what it looked like before I rushed to the airport, where I would assemble the last pieces during my layover:

http://a.imageshack.us/img827/2571/img4243l.jpg

These final shots were taken on my cell phone, so they are not very good to say the least. The system was not very popular at PDX either, which I understand considering how different it is, and that it does not have the polish as my other pieces. I wanted to do a log here though because the design was unique and is not something you normally see on XS.

You can view these and a few more on my website. I'm glad this ones over, I have cooler stuff to post here next. :D

http://a.imageshack.us/img821/3079/82872374.jpg

http://a.imageshack.us/img812/3702/69248237.jpg

http://a.imageshack.us/img265/5964/15236661.jpg

http://a.imageshack.us/img842/4086/dfdfdf2.jpg

http://a.imageshack.us/img163/4831/sdsdax.jpg

http://a.imageshack.us/img534/395/62481209.jpg

http://a.imageshack.us/img413/6114/97762453.jpg

http://a.imageshack.us/img827/6351/sdfes.jpg

http://a.imageshack.us/img843/4894/89841727.jpg

http://a.imageshack.us/img833/289/untitlfsed2.jpg

http://a.imageshack.us/img265/6098/dsdsddsd2.jpg

http://a.imageshack.us/img541/1574/agcs.jpg

http://a.imageshack.us/img831/8120/ccds.jpg

http://a.imageshack.us/img843/4894/89841727.jpg

http://a.imageshack.us/img829/8582/sdadz.jpg

http://a.imageshack.us/img185/1052/addce2.jpg

http://a.imageshack.us/img704/9454/adsdxe.jpg

You don't see too many custom jobs that make use of texture as part of the design. Nicely done :D

Nice result except one thing. Purple lightning imho seems out of place.

Great job :clap:
I think violet lightning will be a bit better, but thats just my own personal opinion.

Holy:banana::banana::banana::banana: man lol you honeslty are an enthusiast with true skill . That just looks pure ill. Wow is all
I got to say , out of all custom builds , hands down you are the most creative and beat IMO .

Thanks for all your comments, guys (and thanks Aedubber). It's a case mod, so you don't have to like it--and honestly I like to hear it when y'all don't. Personally I don't like many things about this mod. I wanted to do something original (pink lighting included, which did not show up well on my droid's camera), not because all those high-class TJ07's are bad (they are amazing, and I am particularly in love with Polarity at the moment) but because I didn't want to get stuck in a groove of just doing stuff like that.

Some highlights for me about this project was fitting a decent-performing cooling solution into the size of my first blue-ray player, and working with different layers of aluminum and acrylic with hand tools. I do like how the cords are not exposed, and the layout of the components. Overall in monochrome I like the design.

Some of the things I don't like (besides my terrible pictures) was the lack of synergy between the colors. I think the materials worked well together, but the polished aluminum, purple screws, and pink lighting approach more into the circus realm than aesthetic art. I also don't like how I rushed at the end and left some edges and wiring pretty rough. It could be much much better, but I learned quite a bit from this project, and the goal of it was an exercise for me I feel like it was a success.

Hey NFC, Despite the rather strident clash between the purple screws, I think it turned out great. One thing I really admire about your works is that even though you usually work in the standard upright rectangular formfactor, you aren't constrained by it. Those fancy murdermods are pretty and all, but I don't think a couple of OTS laser cut panels and sleeving are all there is to a great build.

I can see some spots where your usual standard of work feels rushed, but even so, it looks amazing and if it wen't for the fact that shiny metal means endless cleaning and polishing, I'd be honored to have a piece like it on my desk. Those people at PDX are just silly. xD

And the etchings are spotless as usual. Cyborg hands give unfair advantages.

4 words to descibe it, amazing I love it!!

Wow, this is an incredibly impressive display of ambition as well as craftsmanship. I really admire your work.