[Project] Zero Eight

[TMonte]

01/27/2008 - Update

Made a good bit of progress today...

- Hacked and installed a heatsink for the mosfets
- Installed SB heatsink
- Installed a backplate for the CPU
- Mounted the FuZion
- Blended the pump outlet transition
- Sleeved three of the fans, the pump and the 8-pin extension
- Final mount of the radiators
- Mounted the prepped board in the chassis
- Installed PSU, optical drive and HDD
- Installed loop tubing



Enzotech copper SB heatsink. Attached with 4-40 screws with flat washers, rubber washers and Ceramique.





I didn't take pictures of the process in making the mosfet 'sink, sorry. What I did was take a generic aluminum heatsink for a PIII and cut it to size, then drilled and tapped holes to bolt it to the board. The rough dimensions are 25mm X 60mm. I used a #43 drill bit and a 4-40 tap. It's attached to the board with 4-40 x 1/2" machine screws with a flat washer and rubber washer on the backside. Ceramique is the TIM.








Test fit of the tube from the FuZion to the MCW30. Later in the build I ended up shortening it by 2" to reduce the flat spot in the bend a bit.





Thermalright backplate from their 775 "bolt-through" kit. Mosfet heatsink bolts to the right.





SB heatsink bolts...





Stock D5 outlet transition as molded.





Outlet transition blended with a little Dremel action.








The rest of the shots from today's update are from the final build in the case. As you can see, the rads, motherboard (w/ CPU & RAM) and video card were installed at this point. The remaining pics show progress through to where I am now...






























Obviously, I have to finish wiring everything up, then I'll be reattaching all the plastic trim pieces, bezels, etc. Once all that's done, I'll fill the loop and leak test. Most likely I won't get to that until later in the week or next weekend, due to work and some other stuff. Let's hope I have enough pump for this loop.


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02/01/2008 - Minor Update

Here are some shots of the wiring work I did last night. I've also cinched down all the tubing with zip ties.



A couple splitters I made for the radiator fans. Three-way for the lower, two-way for the upper. They wire up to the Sunbeam rheobus - 1 channel per set of fans.





A shot of the wiring with the three-way splitter for the lower radiator fans. It gets uglier, don't worry...(and will get even worse later in the build )





Tubing finished. I shortened the FuZion to MCW30 tube another 2", and seems to have solved the flat spot issue.







Note the ancient, funky looking IDE cable. I split and flattened it like 6 years ago and it keeps moving with my systems. The slight yellowing shows its age (no smokers around). I'm pretty sure it's the oldest part I still use.





Rheobus wiring. I soldered and sleeved the three extensions. They're zipped up to the side bracket to keep things tidy. Of course I have to add 1 more for the exhaust fan.





Wiring is getting nastier. Still under control, and the side panel does latch on without too much trouble. We'll see what happens when I get to the port/control panel wiring a bit later today.





Angle shot. The wiring is hidden pretty well to this point...





Power supply wiring kept to the absolute minimum, which I like. The 8-pin 12v+ wiring is hidden really well up top by the radiator and tubing, but it's attached (see other shots).






Be back later with another update and more pics!