The ~100lb Project

[sfxs]

A work-in-progress build log.

The goal of my project is to create a well designed case and watercooling system that will serve to cool my newest pc build for the next ~10 years. I am aiming for a system that is sturdy, quiet, and durable. I am relatively new to water cooling, but I have been researching it pretty much constantly since the beginning of July. With these goals in mind, I have chosen the following components:

~ Casing ~

• Yeong Yang - YY-0430 Cube Server Case
  1. link - retailer
  2. link - a review
  3. comments: I needed a considerably large case, and was not keen on full-tower style cases. It came down to either this case, or the MountainMods U2-UFO Opti-1203. Chose the Yeong Yang in the end since I preferred steel over aluminum.
• Two sheets of 5052 Brushed Aluminum 24"x12"
  1. link - retailer
  2. comments: for use as a custom backplate to mount PSU, switch relay, and fan; also to be used for other mounting brackets.
• Four Scythe Anti-Vibration HDD Stabilizer 2
  1. link - retailer
  2. comments: I was originally planning to use an internal raid enclosure, but I cut down to only four disks and this should be quieter and cheaper
• Handles - very large handles
  1. link - retailer
  2. comments: this case is going to be heavy, and I needed some handles to make it less unwieldy - these handles are BIG
• Lots and lots of little bits
  1. cable clips and ties
  2. vinyl edging trim
  3. foams and tapes
  4. more nuts screws and bolts than I can keep track of

~ Water Loop ~

• Iwaki MD-20RZT
  1. link - retail
  2. comments: I considered dual DDC's, but in the end preferred an AC pump, and one that would definitely last me a Long Time.
  3. update: using these to mount to case: 6772K811
• Theromochill PA120.3
  1. link - retailer
  2. comment: hail to the king, don't think this choice needs explaining.
• AquaXtreme MP-05 SP LE
  1. link - retail
  2. comments: can't really define why I chose this over the Storm
• AquaXtreme MP-1
  1. link - retail
  2. comment: well rated, chose over Swiftech
• Masterkleer 7/16" ID 5/8" OD Tubing
  1. link - retail
  2. comment: fits well on the 1/2" fittings
• Fittings
  1. pair of brass reducer couplings 3/4" to 1/2"
  2. PVDF T-fittings, barbs, and couplings
  3. nickel-plated brass fittings for radiator and blocks
  4. machined Delrin fillport from Petra's
• Liquids
  1. Wal-mart distilled water (lots... never want to go again)
  2. Zerex Racing Super Coolant

~ Air Cooling ~

• Twelve Yate Loon D12SL-12
  1. link - retail
  2. with air filters
  3. comment: looking for low noise, quality fans
  4. update: added 4 more
  5. update: with vibration dampening gaskets
• Four Scythe "DF series" 92mm Super Silent Fan - L Speed
  1. link - retail
  2. with air filters
  3. comment: needed two 92mm fans for back of the case
  4. update: added 2 more
  5. update: with vibration dampening gaskets
• SwiftTech MCX159-CU
  1. link - retail
  2. comment: needed a decent northbridge cooler, also some Swiftech bga ram sinks
• Two Sunbeam 5-1/4" Rheobus
  1. link - retail
  2. comment: needed to control the absurd amount of fans I am ending up with
     

~ Electrical ~

• Circular-Pin Relay 12 VDC
  1. link - retail
  2. comment: read stories about those ready-made relays exploding, figured I'd make my own
• ABS Enclosure 4.3" H x 3.1" W x 2.6" D
  1. link - retail
  2. comment: can't be having exposide 115v AC around the case

That's all I have planned for components at this time.

-sfxs

[sfxs]

Usually end up hurting myself on every major project, figured I would keep track for entertainment here.

#1 - 07/24/2006
First-degree burn from a soldering iron while making the relay system, because .
- It wasn't heating properly so I somehow switched into an 'it isn't hot' thinking mode and mishandled it; lesson learned... until next time .

#2 - 08/08/2006
Took a sizable chunk out of the top of my hand while testing the pump and cleaning/flushing the radiator.
- One of those injuries you can't quite place exactly where when or how you got it.

-sfxs

[sfxs]

Every build log needs pictures! once I figure out how to properly focus my borrowed camera, I will have lots of them.

Radiator cleaned and fan-mounted.
-image upload expired so removed for now-

Reducer couplings on pump.
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Handles!
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Handle screws - four sets of the "big stuff" hold on the handles, while 7 of the teeeeeny ones hold the top to the case .
-image upload expired so removed for now-

Top of the top, mounted w/ radiator, fillport, and handles - sorry for blurriness.
-image upload expired so removed for now-

Underside of the top - sorry for blurriness.
-image upload expired so removed for now-

Pump relay assembled.
-image upload expired so removed for now-

Inside of the relay box.
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Pump mounted to the case on bubble mounts.
-image upload expired so removed for now-

-sfxs

[creidiki]

Jesus, thats some big-ass handles o.Ó

Big case too.

[gert_bobo]

can't wait to see some pic's of this monster
and maybe u want to put some big ass wheels under it too? in case u want to spare your back a little bit :p
Greetz Gert AkA B0B0

[sfxs]

The case does come with 4 plastic casters... maybe if I have some money left over I'll put some big fat wheels on it, like these .

Question - how important is the foam fan gasket on a PA120.3? 3 YL's in pull.

-sfxs

[creidiki]

Pretty important, the best rad in the world aint much if you dont have a good seal between the fans & rad.

Personally I go the extra mile and add to it to make extra sure...

[sfxs]

Pump relay is built and test.
Pump fittings are assembled and tested.
Radiator is cleaned and flushed.

Got my fans mounted to the radiator and my radiator mounted to the case top; secured the handles too with fender washers - it is solid. Pictures will be forthcoming soon.

Things I learned: I hate RotoZip, Jigsaws are what you need for cutting metal, stepper bits work well on metal, and hole saws without guide bits are the devil.

I decided to use these Neoprene Bubble-Style small load mounts to mount the pump on the bottom of my case. When I have it mounted I will report on their vibration reducing capacity.

-sfxs

[Xeon th MG Pony]

Ooooo you'll love them mounts they work awesome only thing that beats them is the gel filled ones. They use the gel to dampen ANY vibrations from out side environment to a laser deck for measuring and they work stupidly well, I was temped to grab some but just to honest, I couldn't, not bad price either for the neoprene.

[sfxs]

Mounted the pump.
Created a new backplate for PSU area (never comes out perfect ), also painted the plate.

Question - does anyone know of good/free hosting I could use for hosting photos of this project?

-sfxs

[Xeon th MG Pony]

FileZilla FTP server from your machine?

[Grinch]

Question - does anyone know of good/free hosting I could use for hosting photos of this project?

-sfxs[/QUOTE]



http://www.supload.com/

[septim]

Ooooo you'll love them mounts they work awesome only thing that beats them is the gel filled ones. They use the gel to dampen ANY vibrations from out side environment to a laser deck for measuring and they work stupidly well, I was temped to grab some but just to honest, I couldn't, not bad price either for the neoprene.

$6.87 each? crazy expensive but should be worth it item...

[sfxs]

Some pictures finally uploaded (check the third post).

-sfxs

[mitftw]

Sorry, but I couldn't help laughing when I read this:

hole saws without guide bits are the devil.

Hope you didn't ruin anything! Only use a hole saw with a pilot drill, and make sure there is absolutely no "wiggle-room" when you cut. Use lubricant too. Otherwise, they run wild and your stuck hoping the hole saw won't fly off in your direction.

[illmatik]

The case does come with 4 plastic casters... maybe if I have some money left over I'll put some big fat wheels on it, like these .

Question - how important is the foam fan gasket on a PA120.3? 3 YL's in pull.

-sfxs

Wow with Fat wheels like that you might as well rig a seat and steering device

[Just Some Dude]

Big wheels make your computer go faster.....