The Build Begins

I've officially started on this project, so its time to start updating this log. I really wrestled over whether or not to go with air cooling on this one, or stick with water. I've been water cooling now for 6 years. I started into water cooling mainly for silence more than performance as I'm a 24x7 overclocker and not a bench-marker. I also hardly do any gaming anymore, so I'm not looking to upgrade my GPU anytime very soon. I plan on sticking with my GTX260. Now that some good GPU air coolers have finally come out, I decided that I'm going to give air a chance again. I designed this case completely with two different versions, one for water that I rendered in the posts earlier, and one for air (actually two different air models). I finally settled on this design as I think it gives me the most compact design I can come up with that also should allow for good airflow and easy wire management.













I bought a Promilatech Megashadow for the CPU, and an MK-13 for the GPU (I've still got the 3 MCR220 rads, and once I'm done with this project, if I am pleased with the result and noise level, I'll end up selling them. Since I already paid for them, I figure I will keep them in case I decide that I'm not happy with the air cooling and result). If I am going to go air, I am going to go high end.

Plans

As is my usual method, I plan everything down to the nth detail, and print out plans from the Sketchup design. I admire the guys that just pull this stuff out of their heads on the fly, but that isn't me. I like doing the design work first and then building based off of my designs. Once I design everything the way I want it, I take each piece and make dimension plans, and then print off the dimensions for each piece. I did an expanded view of the metal base for the case, and then drew out each piece in flat dimensions so that I would know what to cut out of my 3' x 4'-16 gauge (about 1.3mm) aluminum sheet. This sheet plus another smaller 1' x 2' piece of 12 gauge only cost me $40 cash at a local sheet metal shop. I found a powdercoater online in Florida that is very reasonable on his rates. I plan on having the aluminum powder coated probably in matte black. I would like to do that aluminum in a bronze color or the like, but I don't think he works in any colors like that.









Main Panels Started

I started cutting the main panels out per my plan printouts.





I found as I've seen others suggest that painters tape works very nicely when cutting out holes. I am using my scroll saw, Dremel in places, and a great set of small files to make the cutouts.



Center Support and Spacer

This is the center support for the inside panels. It also gives a space behing the MB tray for air intake for the PSU, and room to run wiring. I used 1/2” 16 gauge square tube as that is what is readily available. I cut my pieces, and used JB Weld to join them together. I could have had a friend weld them, but I don't really need a lot of strength here, and welding can make a real mess.



Bending Aluminum

I wish I had access to a professional metal bender, but with some work and a lot of clamps, my $30 Harbor Freight made in China special metal brake got the job done. The biggest problem with this brake is that when you are bending end folds, the metal wants to slide back out of the brake. Using two 3' clamps against the tray and a screwed down 2”x4” did the trick to keep the metal from sliding back while bending.








Here is a rough fit of the pieces so far. I put a 1' ruler and a paint can to give you some size perspective.





My next step is to drill and countersink holes to screw the MB panel and other panel to the center support. I then will cut out the holes in the bottom panel, and then work on the back panel. That is going to be a bit of a chore.

Thanks for stopping by.