I started this thread in the water cooling section but it really belongs here. My plan is to build a case to hold my new PC. The case is based on a MM Horizon case, only a little bigger overall ( 2' cube ). It will house a Intel quad core processor, 2 8800 series video cards and 2 water loops for cooling. I am looking for comments/ suggestions on the design. Also will be looking for any tips/suggestions on the fabricating process. My plan is to build the frame out of 1/2" square AL rods screwed or welded together. The panels will be a mix of AL panels with cutouts/ mesh inserts and Plexiglas panes. I plan to use a off the shelf motherboard tray and 5 1/4 external bays. the case is split into a top and bottom section, the top being 10" and the bottom 14". The top will house the MB, external bays and probably the PSU, the bottom will house the 2 radiators and 2 pumps along with some kind of bays for internal hard drives. My plan is to make the bottom section of the case mesh all the way around or at least on the 2 side panels and mount the radiators behind the side mesh. My reasoning for the mesh on the bottom is switching radiators/fans without having to re-cut panels if i switch in the future. My concern is if I have the bottom all open like that will it cause airflow issues as is not running through ported vents and will be mostly open? I would think being all open would allow a lot of free flow of air but would that cost me in performance?



Well here is my first attempt with a CAD program:






The colors are not some mad fashion sense, more to keep the different parts identified, I imagine I will paint it black.
I have 2 ideas for the top venting not sure how I will go there, both would support 2 120mm fans. The front panel has holes for 2 - 5 device 5 1/4 external bays(MM bays probably), 2 120mm fans and 2 small cutouts (may fix in windows?) to see 2 swiftech micro reservoirs. Back of the case has cutout for a slide in MB tray, 120 mm fan and power supply, i will probably have to build some internal support for the PSU, and possibly more for the MB tray. For the sides i am thinking 2 pieces the vented bottom part and top transparent Plexiglas. Bottom may just have 4 casters.


Questions:

How thick Plexiglas and AL panels? For the front should I have a support frame for the drive bays, and for the PSU in the back? Given that that top panel will support 2 or 3 120mm fans should it be thicker than the side windows?

Sources for the support frames/panels I have found a few places on-line listed below though for the AL parts at least I am going to try and find them locally, probably won't have it at a home depot type place but maybe some kind of metal fabricator, not sure never tried to buy anything like this before.

AL
http://www.onlinemetals.com/index.cfm
http://www.brunnerent.com/default.asp?reset=1
http://www.jlindustrial.com/cgi/jisrhm

ACRYLIC PRODUCTS
http://www.delviesplastics.com/


What can I use to weld the AL rods together with? Looking for something simple I do have a large propane torch that I use for cooking. Could I get rods of AL sodder?

Thoughts on airflow? I will have 2 120 mm fans on the top half of the case sucking air in and 4 120 mm fans (2 top 1 MB tray 1 back pane) blowing air out. The bottom half of the case will have at least 6 120mm fans attached to 3 PA 120.3 radiators sucking air in from the sides of the case. Give the open mesh bottom half I was not planning any fans blowing out. Should I? There may be an additional fan or 2 blowing through the hard drives and or on the pumps.

Parts, MM has MB trays and 5 1/4 drive bays, I have also gotten a link to some Li Lang parts, any suggestions on other 5 1/4 bays or mountings, same for MB tray, these are things especially the MB tray that I would want pre- built.

Any suggestions comments? This is my first attempt at a project of this magnitude so I am trying to gather as much information as possible before I start. Thanks for any help.