Guide: Waterblock Building and Designing
So You Want to Build a Block?
No problem, but it isn't as easy as just carving channels? Taking a look at some of the best blocks they don't seem to simple. But most blocks can be built with patience, time, and a drill press.
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Tools
when building a waterblock you will need some tools. Depending on what materials, some work, some don't work, and some work but not well enough for good usage.
* The Dremel - The dremel can be used for cutting into blocks, but it isn't great and is quite sloppy.
* The Drill Press - The best bet for your average block builder, a good drill press with a good vise and most design are possible.
* Jigsaw - Not advised for making blocks, but it can be used to cut bar stock for block building.
* Hacksaw - Another item for use like the jigsaw, but less sloppy.
* CNC - A CNC is a very very expensive peice of machinery, and is good to make the best blocks, but most average builders will never get to touch one of these, a local machining shop may or may not own one.
* Taps - You will most likely need a set of taps to thread your block tops to take the barbs for input and outflow.
Materials
Another thing when building blocks to be concerned about is the material you are using. Using www.dangerden.com for a reference, a bar stock of copper that is 2" x 12" x 1/2" is $20 bucks, and around $35 once tax an shipping are added to the East coast, the Pacific may vary.
- CORROSION. THE BIG C! When mixing metals in a loop, like aluminum and copper, corrosion will begin, and therefore it is a good idea to avoid mixing metals.
* Copper - Copper is the best item for the first time and experienced block builder, it is somewhat expensive, but not as expensive as silver. Copper is also quite easy to use with a drill press and works nicely for heat removal. Copper is normally a good item to use as most radiators/heatercores are copper.
* Aluminum - Aluminum is cheap and very inexpensive. Only around $4 for a bar 2" x 12" x 1/2", aluminum is a poor conductor of heat compared to copper or silver. I would only suggest aluminum for testing if you can indeed drill/build a block design.
- A warning about aluminum. Aluminum even when anodized will eventulaly begin coroding your system if theres any copper in it. So for all purposes, only use it for quick testing, or for desiging templates.
* Silver - Silver is the best. Silver is somewhat easy to use and build and offers amazing thermal properties. For the first time or experienced builder, I would not suggest silver because of price. People like Cathar are very professional and know what they are doing, and are quite amazing with silver. If you decide to use silver, make sure you know what you are doing, or have too much money.
Designing Blocks
Now onto designing. Picking and making a great design is the hardest part. The things to look at when building a block are surface area, flow paths, and resistance.
* Pins/Pillars - A common design is to drill holes into blocks to make a standing pillar of metal. With a common repeating of this you end up with a design like the 6002 Swiftech block. These blocks have plenty of surface area, flow is quite even, and resistance is actually quite helpful.
* Od-Ball - The od ball design is by drilling a set of holes one after the other without them touching and then connecting the "dots" to make path ways across were the core would be on whatever you are cooling. These designs have mediocre flow and are high resistance, but work well.
* Fins - Straight path fins are made just by cutting a line across the block from input to output. These blocks have tons of surface area but the overall pressure drop can be devastating to the rest of the loops flow with a small pump.
* Holes - Often used with jets (coming up) simply by drilling holes into the base below the input allows the water to go down to the base, and these designs work well most of the time.
* Jets - A new common item that isn't in the actual metal, but in whatever top for the block you choose. This is basically drilling holes into the top area below the input barb to direct the incoming water onto holes or pins.
* Impingement - Impinge-ing a base is just the process of adding tons of pins for the water to fall on making turbulence and good conditions for the removal of heat from the block.
Topping your Block
Once you design and build your block, your going to need to top it. There are a few good materials that are a yes-yes, and a few definite no-no's.
* Lucite / Acrylic - Both of these materials are clear, easy to use, and somewhat easy to tap for barbs. The only problem is after a time it can begin to crack, though Dangerden does use this for its tops.
* Stock metal - Whatever metal you used, assuming its not aluminum, you may be able to weld/braze another peice on top to keep it together. This is done for vapor phase change evaporators, and does work for watercooling.
* Brass - Brass is a great material for topping your blocks. It is durable, strong, and lasts. Brass can be somewhat expensive to find or buy as it is quite dense.
* Delrin / Acetal - The newest "craze" for topping your blocks. Delrin or Acetal as its called, is amazing stuff. It is durable and moldable. Its very easy to tap delrin, cut delrin, and such. I suggest using this material for your first blocks!
Lapping Time!
Once you've drilled, tapped, created, designed and redisgned your blocks. Its time to use em. No, wait... Nevermind. Its time to break out that wetsand paper and get down and work. This is the part people normally hate to do, I hate to do it myself. Lapping your block is when you simply just sand it and sand it with finer and finer wetsand paper until its ultimately flat and shiny. This also makes your creation look beautiful. Its a little self explanatory so I'd just say one thing...
The time you spend at this step is worth every moment. And don't kill your hands too much before you get to overclock and break out a good FPS on some noob's buttocks. :woot:
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Sooo... Now your creations completed, and its time to show it off, so following all your work its time to have some fun. Mount it up and move it out. And keep building!
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Pictures to compliment designs coming soon.
