Project: OSIDIAS (SFF taken to the extreme)

[craigbru]

Hey guys! I though I'd take the time to repost the planning thread for my next project. It's been an ongoing thread at bit-tech for some time now, but I thought I'd get you guys in the loop. I apologize for the cheap copy and paste job I'm about to do.

I'm also going to repost with everything unedited, and please understand, changes have been made as time as progressed. While some things may seem out of context, it's probably the best way to show the evolution of the project. So, I hope you enjoy it, and I appreciate any comments you might have!

Feb. 6

Hey guys, I'm throwing around ideas for another new case... I've been sketching up some ideas and wanted a little feedback. Keep in mind that what you are about to see, is unfinished, and missing some key details. However, I like the concept, but I want your opinions on how it all fits together.

Okay, here is the core of the case. It's SFF of course, and it's damn tiny due to efficient space usage. I'm planning a DFI X58, SLI, full size PSU, 4 full size hard drives, pico, and watercooled CPU in this little package. Due to it's design, it should also run fairly cool. As of now, I don't plan on deviating much from this except for details like adding mesh, or possibly windows.



I was then inspired by a RED camera cage I saw, and wanted to add a more industrial and sci-fi look to the case. The following is what I came up with. Of course it's subject to revision, but wasn't sure how it all fit together.







Opinions?

Feb. 8

I've been playing around... what do you think of holes? Or maybe some variation of this?



Okay, one more here. I added vents to the side panels. What do you think... too many holes? They will have mesh behind them, with the exception of the most forward hole, that will have a window...



Feb.10

Well, I didn't have as much time as I had hoped for last night, but I did make a few small revisions. I made the side window slightly smaller, and added another opening beside it. Even thought the window is still larger than the rest of the openings, the spacing between them is consistent. Also, I added matching holes the the 'cage'. I'm unsure about the abundance of holes now, but I need the airflow. There will also be mesh behind them, so they won't stand out as much as the vents, for example. Speaking of mesh, I created some mesh with 1mm holes... Lol, talk about a CPU killer! I'll have to revise that...



Now, this next part is just for Xtra@bit-tech. He wanted to see the interior arrangement....









Feb. 14

...and we have a name for this project... It will be OSIDIAS, and I've got to give my wife credit for coming up it. It's sad how much I concentrated on this trivial little detail, but I was convinced that I wanted something completely original. I think I've found it.

Over the last few days I've been making up a parts list. It's amazing how much aluminum will find it's way in to this box. I'm planning on making the outer shell out of a single piece of aluminum. I'll cut all the holes, then bend accordingly. Should be fun, huh? Also, as mentioned earlier, I'm going to braze all the parts together. This will free up any concerns about fastening parts together, and will guarantee a rock solid case. I also like the idea of no exposed fasteners anywhere on the case. This will be a new technique for me, and one that is rarely used in modding in general. I'm sure it's been done, but I can't name a project that incorporates it.

Feb. 16

I managed to get the interior tray about 90% finished over the weekend. Here is a pic of what I've got so far. Most of it will be bent out of a single piece, and the rest will be brazed together.



Another updated pic...

[craigbru]

Feb. 20

Okay guys, I've been playing around with renders. Since I'm using ViaCAD, Kerkythea isn't as easy to use as with Sketchup. I've basically got to export a .dxf, and then import it into SketchUp. However, when I do, not everything gets exported. I'm not sure how to fix that yet, but I'll keep playing around with it. So, the render below is missing a few components...



Feb. 28

Okay, I've got a small update here. I've added the LCD to the front, and an Aquaero to the right side. There's also a new reservoir on the rear, but I've got to finish a little tube routing before you see that.





I probably should have added a few comments. The LCD is capable of rotation and swiveling. Left, right, up down, and portrait/landscape.

One more thing... I've started to order a few parts...

One more small update here. I've finished the interior tubing layout. Simple and efficient...



Mar. 3

I've got about 90% of the details finished on this case. I'm still tweaking though. Last night I managed to make a little more room for larger fans. Originally I was only planning on 25mm thick fans, now I've got room for my monster San Ace 1011's. This thing might have enough thrust to fly. I've also got to do a little more interior parts placement. The Pico-ITx was originally located on the lower right rear, but I've since added the Aquaero to that location. That means I need to find a new spot for the Pico. I'm also looking for room for a Multiswitch, and USB hubs. I'm also thinking of adding a single SSD to the system for my OS. That would make for a total 5 drives. A SSD for the OS, a pair of Velociraptors in raid 0 for games, a 750gb drive for data and backups, and another 750gb drive for the Pico.

Mar. 5

I've got a quickie ViaCAD render here. No time for anything prettier, but I thought I'd show you the color scheme I'm likely going to use. Although my Duality project may be postponed, I loved the colors enough to use them here. Before settling on the orange, I ran through a rainbow of choices, and came back to this. It just stands out. :thumb:



Just a slightly better render...



Mar. 23

Okay, I'm sure you guys are tired of seeing all the lame render pictures in this thread... I assure you, these are different though. Dark~3nergy has put his talents to use for me, and created the following...







Many thanks go out to D~3 for all his time!

Okay, thanks in part to partial inspiration from this thread, I came up with an idea I'm going to expand on. I've long thought about having fun with transparent LCD's, but redders' thread made me consider it all over again. So, it was time for a little experiment. The following is a standard 7" LCD removed from it's housing, and with all backing and polarizing film removed. What we have here, is what I intend to use as the side panel windows on OSIDIAS. For lack of a better term, I'll call them active windows. You can see that as long as there is a light source behind the LCD, dark objects and text is shown through. Granted, colors would be washed out, but the concept is still sound...





This could be fun!

Apr. 22

It's been awhile since I've posted an update. So, I figured I'd get you all up to speed on how I've been spending my time. Project: Hutch will be getting some long overdue attention soon, but in the meantime, I've got some new hardware to play with. Although I've not started an official log, there have been some parts arrivals for Project OSIDIAS.

I've got an Asus Rampage GENE II, Intel i7 920, 6GB OCZ Platinum, and a SilverStone DA1000 PSU freshly delivered. I'll be pairing the new parts with my existing EVGA GTX 260's. There may be a video card switch in the near future, but I'm using what I already have for the moment. Also arriving shortly, will be a slot load Blu-ray drive. All the above parts will be the heart of OSIDIAS, and I'll have a running system long before the project is actually finished.

So, how about a few hardware pics?













As of now, I've got most of my software and games installed. Although I've only been using the hardware a short while, I can tell you this... It's the best hardware combination I've ever used. Everything is rock-solid, and I've not had a single error or glitch in two weeks of a fresh Vista 64 install. I'm really looking forward to getting the CPU on water and hitting the overclocks. Stay tuned!

May 11

Just a non-update update here... In between all of other miscellaneous projects (including current, but not log-updated Project: Hutch), I've been giving OSIDIAS's design a slight tweaking. One of the benefits of delaying the start of a project, is that it allows new and alternative ideas to come out. Ideas that may not have been possible if work was already underway. One of the things I realized, is that I may need to find away to attach all the ribs to the interior of the case. They will need to slide out with the motherboard tray. This will require them to be mounted to easily removable frames of their own. It's not really a big deal, but will require some interior redesign. I've also found the need to widen the case itself by a single centimeter. That change alone allowed for the following...

The biggest idea came to me as a sat at my desk listening to the whine of the fan on the Via pico-itx board in the Rogue. I've got no way to quantify it, but it seems lightly louder than before. So, I've decided to 'Langer-ize" it. In Jesse's outstanding Prometheus log, I suggested the possible use of a Cooler Master Aquagate Viva for watercooling the pico. Well, I'm now taking my own advice. I've found room for a secondary watercooling loop... Utilizing the Viva's pump and radiator, as well as some very creative parts placement, will allow me to ramp the insanity up another notch. Stay tuned for updated sketches...

[craigbru]

June 23

I've been pretty busy lately, but I thought I'd show you one of my interior revisions. I've changed the internal supports to something a little stronger, and changed the layout slightly. In addition, the case is now able to fit most any rad up to 56mm in depth. Also, I've made room for the second radiator (Aquagate) for cooling the Pico, a 3rd fan over the video cards, and finally room for my Wintsch Labs peltier block. I've got to draw the block in CAD yet, but it should fit. Once I get that done I can get the tube routing planned out. More to come!




June 27

I just can't stop revising... I was looking at the newly added 70mm radiator, and I got to thinking... It's just not big enough. Granted it's plenty for the Pico, but what if I ditch the idea of watercooling it, and add another radiator to the main system? Well, with a few small revisions, I now have room for a X-Flow 240. Why the X-Flow? I'll need to relocate the G1/4 fittings, and this rad would allow the most workable solution. I won't be able to fit 120mm fans on the second radiator, but I'll make sure it does get some air. Details are to be worked out on that yet...




June 29

A few changes... No more aluminum exterior. Here is what I'm planning on using for the case itself. You can't go wrong with carbon fiber, right?





Since the case will be formed out of a single piece of material, I'll be experimenting with some reverse molding and vacuum bagging techniques. It's either going to be the coolest thing ever, or a colossal failure. I can't wait!


August 23

As the beginning of this project gets closer, I've been receiving a steady stream of parts and materials. Of those parts and materials, the carbon fiber is probably the most integral. With it, I'm hoping to take what I hope is a pretty cool concept to begin with, and take it to the next level. While there are many cases made of aluminum or even wood, a case constructed of carbon fiber is a much rarer occurrence. Fellow modders Langer, MKmods, jhanlon303, and rendermandan, have all worked with it in some capacity, and I owe them credit for inspiring me to use it here as well. With that in mind, I went ahead and ordered an orange carbon fiber/kevlar blend. This particular fiber will be used for the side panels and ribs on OSIDIAS.

So, without further delay...



And one more pic...



More to come!

[craigbru]

September 17

Despite the lack of 'real' work done on this project, I've still been collecting a steady stream of parts. One of the most anticipated of these parts arrived in a box from Aqua Computer in Germany. Inside was the electronic heart of OSIDIAS. These parts will be responsible for monitoring almost every electrical aspect of the case. From fan speeds, to temp monitoring, to lighting, and even powering up and down. Although I've got much detailed planning to do to make this all happen, I'm looking forward to the challenge.

So, what did I get? Here are all the parts laid out for inspection.



One of the most critical parts, is this Multiswitch. It is controlled via USB through the Aquasuite software. This will be the electrical switching station for anything having on/off requirements. The lighting would be a good example of this.



Next up is the new Aquacover for the DDC pump. All specs aside, it was just too damn good looking not to throw in the system.



Now we have the new flow sensor and inline temperature sensor. Both of these parts are very high flow, and low restriction.



And finally, we have a VFD Aquaero. This is really the brains of the operation. Everything starts here. All monitoring and control runs through here and the Aquasuite software via USB. The Aquaero will be linked to the secondary Via pico-itx system, and a touchscreen LCD. These components working together will allow seamless and automated system control and monitoring.



One last thing worth mentioning, is the Powerbooster modification made to the Aquaero. This addition is a special cooling block and a small hardware modification of the Aquaero which will allow you to use a Laing pump on fan channel 1. The other three channels will be able to handle 15W instead of 10W. This increases the available overall power to 45W. It's more than enough in my case.



Now, to go play with some hardware...

[craigbru]

Oct. 24

Although I've been busy with other things, I'm still taking the time to tweak the internals on OSIDIAS. Things are so tight in there, I've got to have the placement of every part planned in advance. I really don't want to get started on something, and then realize I've got to remake a part. The material budget on this case is much higher than in my last projects, and I want to get it right the first time.

So, with that in mind, I've finally got the tubing layout finalized. Everything has sufficient room, although i had to get creative on parts placement. The newest addition to the loop was the Aqua Computer flow meter. That's what you see partially obscuring the CPU block. It's a decent sized part, but it's a worthwhile addition. You can also see that I reversed the pump's position. I've got that great looking AC top, and I intend to show it off a little...

With the tubing taken care of, now I need to finalize cable routing, and various electronic component placement. I'll work on that as I continue to work on Project: Hutch.

[craigbru]

Dec. 18

There's a funny thing that happens when you are planning a project way longer than you had anticipated. Changes. Changes happen. Many changes actually. Although I've stood by the basic form factor I had first envisioned, things have been in a constantly evolving state. A tweak here, a tweak there, in the ongoing pursuit of perfection. Every last detail is being planned and thought out in advance. Just when I think I've got it nailed, another idea pops in to my head, and I'm revising again. Now, I can't keep this up forever, and I'll soon have to commit to a design plan, but until that happens I'm going to have a little fun.

So why the rambling intro? Well, I've got another idea. This one is slightly more costly, slightly more unique, and way more insane. In fact, this sort of thing wouldn't even have been very economically feasible even a year or two ago. What sort of thing am I referring to? UMPC's... Yes, why stop at 2 systems in a single machine, when you can have 3. Do I have your attention now?

Here's what I'm thinking... As OSIDIAS stands right now, I've already got a 7" touchscreen on the front. This screen was to act as the control interface for the pico-itx system, which in turn monitors and controls almost every aspect of the main system. If I replace that touchscreen with a UMPC linked via a wireless connection to the pico, I can retain the same functionality through software. The biggest advantage then, is the ability to remove the UMPC and control the system remotely. On top of that, I've got still got all the original functions of the UMPC itself. Overkill? Nah, there's no such thing! So, stay tuned for updates as the plan gets revised and implemented. Insanity has reached a new level...

I suppose you want to see the UMPC I plan on using, huh?



http://www.myviliv.com/eng/product/x70ex.asp

[craigbru]

I really need to make an update here! The Viliv has arrived, and I'll be doing a video review of it shortly. In the meantime, I've been playing with other ideas. You see, with the addition of the UMPC for system monitoring, I needed a reliable way to relay information to it. I have been toying with bluetooth, but have a 2 device limit on networking them. So, wi-fi was the next obvious choice. That brought it's own set of issues. The pico must always be on and networked, the main system may not always be, and the Viliv must also always be networked. I also want to ensure the Viliv and pico always have internet access. Not that big of a deal, right? Well, Samurize needs static IP's for relaying information, and while that is great for home use, what about when I go to a LAN? The IP's are subject to change, and that would throw everything off.

So, what's the fix? How do I get static IP's? The easiest way is to use an access point, in this case, a wireless one. Everything is wireless capable anyway, so I can assign each adapter it's own IP, and they won't change regardless of where the system goes. That's where this comes in to play... It's the smallest AP available.



Okay, with that out of the way, I have 3 devices inside of OSIDIAS that need ethernet connections. The main system, the pico, and the access point. That leaves the need for a switch. This unit from Bytecc is the absolute smallest I could find. Everything must be internal!



Believe it or not, I've found room for both of those components inside the case without inhibiting airflow... When I get a chance I'll get some updated pics posted. Stay tuned!

[craigbru]

I had a little time over the weekend, so I thought I'd make something special for everyone that has been following this project. This is a video walkthrough of OSIDIAS. It explains how some of the components fit together, and I cover some of the design basics. Although I've left out a few details, I think you'll understand the project a little better. Enjoy!

http://www.vimeo.com/8832516

[pizan]

I have liked your work and the past and this one is looking to be epic, but you are f**king nuts!!!

I like the AuqaComputer parts. Do you have to order them from Germany or is there a local reseller?

[craigbru]

I have liked your work and the past and this one is looking to be epic, but you are f**king nuts!!!

I like the AuqaComputer parts. Do you have to order them from Germany or is there a local reseller?

Thanks man, I appreciate it!

I got the AC parts from Germany, as I couldn't find any reseller stateside. I got a pretty good deal on the parts though, as they were running a summer special at the time. I also spoke with Shoggy before placing the order, and he was able to help me out with price as well...

[illidan]

pure perfection!

i'm gonna follow this all the way

[craigbru]

pure perfection!

i'm gonna follow this all the way

Thank you! It should be a hella fun ride!

[Liderc]

Great renders, looking forward to seeing this play out.

[atomic ferret]

Wow, incredible renders. I cannot wait to see this happen.

[josk1]

i'm ready for more

[craigbru]

Great renders, looking forward to seeing this play out.

Wow, incredible renders. I cannot wait to see this happen.

i'm ready for more

Thanks guys! I wish the renders could have been done with the carbon fiber textures, but at the the time they were done, the case was still going to be just anodized aluminum. Oh well, I'll be looking at the real thing soon enough!

[Seu]

Sub'd ! it's gonna be awsome

[aka_GK]

subd and waiting for moar

[craigbru]

Sub'd ! it's gonna be awsome

subd and waiting for moar

Thanks guys! Today I bought the last of the parts needed to officially start. I have vacuum bagging equipment on it's way!

[Red-5]

Have followed this project on Bit-Tech and it's good to see it on here.
Cool case design and renders too. Looking forward to seeing more.

[craigbru]

Well, disturbed13 at bit-tech managed to pry an upcoming sponsor out of me...

So, since the surprise is out there, I might as well make the official announcement. I've been speaking with Ron Rogers of Romaxx CNC, and he's been generous enough to sponsor a HS-1 machine ready to run. I'll be using the machine on this project, as well as any future projects where applicable.



The HS-1 is a very solid tabletop CNC, and will be able to handle most any job I throw at it. I wanted to work with Romaxx for several different reasons. The first of which is the standards by which their machines are built. There's no doubt they are solid. The second is the support Romaxx offers after the sale. They stand by their machines, and are quick to take care of any issues should they arrive. Lastly, there is a pretty good community of users on the Romaxx forums that are willing to help and share their experience. All of these things added up to make it an easy decision for me.

I'll keep everyone updated on the machine's arrival, and I'll certainly post pics as soon as I can!

[weston]

good luck with the carbon fiber, that can be tough (and expensive) to work with!

[pingpong1455]

slightly off topic question but where could you get an aquero in the u.s. ??

its a bit late to order one now (got nzxt sentry instead) but i just wanted to know for future reference

[craigbru]

good luck with the carbon fiber, that can be tough (and expensive) to work with!

Thanks man! It will be a pain, but the results will be worth it. There's nothing quite like the look of real carbon fiber under a smooth finish.

slightly off topic question but where could you get an aquero in the u.s. ??

its a bit late to order one now (got nzxt sentry instead) but i just wanted to know for future reference

Sidewindercomputers.com is the only one in the US that carries Aquaero's to my knowledge. I had to get mine directly from AC in Germany though, since I wanted the VFD version.

[Wezly]

I love the pico-itx part of this build.

Can't wait to see it progress!