Daniel's murderbox - with a sLight twist

[breathemetal]

Very nice Charles!

[Henry8601]

Wow - yet more amazing bits of work Charles. It's always great seeing the next thing that you come up with!

[hiiyah777]

Hey Charles, not to be too off-topic here, but just letting you know that I've FINALLY posted my work log today. Have a look if you'd like:

http://www.overclock.net/case-mod-wo...d-worklog.html

And keep the updates here coming, I check three times a day for updates. (Does that make me an addict? Surely not!)

[charles_h]

Cheers Guys!

Hiiyah: Awesome! I’m really looking forward to following your build!



Project Update:

I will now destroy this innocent piece of Aluminum (sensitive viewers may want to avert their eyes).




The Aluminum plate that will be used to fabricate PLED structural mount.


The first step is to prepare the internal plate by removing the angled edge – it’s not needed.

Cylindrical Aluminum standoffs will be used to mount the internal plate to the existing TJ07 vertical structure.





Since the closest length is 1” and they’ll need to be shorter, they’ll have to be filed down a bit – more on that later.


We’ll start by cutting the angled edge off the plate with a jigsaw. I’ll secure the plate and freehand cut this sucker.






Sometimes I’ll use a cutting guide but this cut is pretty simple – I’ll take my time so as to avoid a Freudian slip.




Oh no; he didn't just say that...


Ok, enough foolishness... time to get down to business.









Once the cut is done, I’ll clean up the edge with a bastard file and Emory cloth.



The next step is to build a template for the PLED mount holes. For this I’ll use a piece of clear Plexiglas.






I carefully measured the PLED mount holes and created an accurate paper template which I then transferred to the Plexiglas. The next step is to overlay the template onto the plate and lineup the grid with the opening.






Once the plate is marked and triple checked, I’ll drill the PLED mounting holes. No need to show drilling shots – I’m sure you guys know what that looks like.






Since we’re short on available space yet want to use a clean front facade, I’ll oversize the display openings in the internal plate. This will provide the clearance needed by allowing us to countersink the top black portion of the PLED flush with the outer edge of the internal plate - thus gaining the critical 1.5mm needed.





Confusing? I show.


I’ll start by setting up the plate and preparing it for the operation.





Next, I’ll grab my trusty Dremel…





I’ll use the wood as a guide and carefully…





Wait a minute!


Mr. Dremel, you are too puny…

This task calls for pure spinning destruction... the kind that only the RotoZip can provide.




Oh hell’s yeah.


Now that I'm using the RZoD, I really need to make sure the cutting guide is accurate. With the right bit, a RotoZip is pure destructive pleasure but you cannot freehand cut a straight line - unless you're a brain surgeon maybe!




Now we're ready!







Sorry, no live action shots - I can't RotoZip with one hand (well, I probably could but I don't want to end up with one hand!).




One line down, 11 to go…





The first one is done.





All done!



Ok, time for a cigarette (even though I don’t smoke). I’m a simple man of simple pleasures; using the RotoZip is one of them. The one downside is of course the cleanup. While mostly contained, I do find frags as far as 10 feet away.




ShopVac... front and center - Stat!


Next, I’ll countersink the mount holes and test fit the PLED using temp bolts.






I’ll use rubber grommets as spacers for now, these will likely be swapped for nylon spacers later.








That’ll work!







Finally, I’ll lay the facade in place to get an idea of final look.






Well, that’s all for today. The next step is to mount the internal PLED plate to the existing vertical structure and attach the facade. This should complete the mockup and fabrication of the PLED mount - then I can get the measurements needed for the side panel water jet cutting. The next phase will be to design and construct the lower section of the LC loop and then it’s off to powder coating. Somewhere in there lies the new concept that I’m super excited to reveal!

Until then - thanks for looking in.

[IcEWoLF]

Very nice charles, that looks amazing!

[Yil]

Hi Charles,

when will they be available in the Murdermod shop??

Gr Yil

[ultimeus]

Nice update Charles, I see murderbox signature on this too

[dingdong555]

Charles my friend, you're work is beyond outstanding. I'd kill to see what you can do to case in 10years

Perfectionist......that you are spedo man!

[hiiyah777]

Looking brilliant as always, Charles!!!

[moogle]

bastard file

Nice to see more great work by you charles

[dsecrieru]

I love big updates!

Awesome display of your skills and tools man. It's all coming together quite nicely. I can even see the Light at the end of the... tunnel, yes tunnel.

Daniel.

P.S. I hope your health's better and the flu is gone.

[Dangals]

Charles you are a wonder - you make everything look so incredibly simple and on top of that you make it easy (and enjoyable) for everyone to follow.

My hat of to you sir

[SNiiPE_DoGG]

Charles I take it you have your waterjet machine recently setup so there is very little damage to the slats on the bed, or do you use a protection coating? the one I have to work with here at school is very torn up and it rips the finish on the panel up.

[theseeker]

Charles,

In addition to your other many talents, it is apparent that you are jigmeister too! Beautiful work my friend!

[charles_h]

Very nice charles, that looks amazing!

Thanks IceWoLF - Welcome to XS.

Hi Charles,
when will they be available in the Murdermod shop??

Gr Yil

Hey Yil my friend.

I don't think they will be a regular stocked item. Perhaps special order...

Nice update Charles, I see murderbox signature on this too

Cheers ultimeus!

Charles my friend, you're work is beyond outstanding. I'd kill to see what you can do to case in 10years

Perfectionist......that you are spedo man!

Thank you James.

You won't have to wait 10 years. As for the killing part - well, it is murderbox...

Looking brilliant as always, Charles!!!

Cheers Jason!

Nice to see more great work by you charles

Cheers moogle - your avatar is one of my favorite cat pics!

I love big updates!

Awesome display of your skills and tools man. It's all coming together quite nicely. I can even see the Light at the end of the... tunnel, yes tunnel.

Daniel.

P.S. I hope your health's better and the flu is gone.

Cheers Daniel - feeling a bit better thanks. Still not 100% so I'll have to reluctantly take it easy this week... something I hate having to do. I'm used to running at one speed.

We'll get there my friend.

Charles you are a wonder - you make everything look so incredibly simple and on top of that you make it easy (and enjoyable) for everyone to follow.

My hat of to you sir

Thank you Daniel, I really appreciate your kind words. The beauty of the worklog is that you don't see me measuring the same thing 10 times. Anyone watching me work would surely loose their marbles! "just cut the damn thing...!" they'd say.

Charles I take it you have your waterjet machine recently setup so there is very little damage to the slats on the bed, or do you use a protection coating? the one I have to work with here at school is very torn up and it rips the finish on the panel up.

Sniipe my man, I'm going to pass on my secret but you have to promise not to tell anyone...

Styrofoam.

Charles,

In addition to your other many talents, it is apparent that you are jigmeister too! Beautiful work my friend!

Cheers Rocky.

I'm a huge fan of jigs! Makes for a lot of setup time but IMHO, always pays off.

[HuffPCair]

I wish I had skill like this. Amazing build so far, looking real good.

[twwen2]

Amazing work Charles, simply wonderful!

[dualbrain]

Very good fit of the double-plate-display combo.

[masxerofkartis]

What's that bit you keep attatching to the jigsaw and what is its use? Other than the blade ofcourse

[elite.ire]

nice work i was wondering for a while there why you had made two of them alu panels, but alas all is now clear

[jimmyxxx]

dam fugly work , just kidding, you know that i know you are the best .

[Groveling_Wyrm]

AMAZING attention to detail, Charles! This should be yet another beautiful creation for you.

Thanx for sharing with us!

[PaRn ssR]

amazing TJ07. dream of the Temjin

[charles_h]

Cheers Guys!

I really appreciate your words of support - they totally motivate me.

What's that bit you keep attatching to the jigsaw and what is its use? Other than the blade ofcourse

Sorry, which piece are you referring to?



Project Update:

Now that the PLED is in place and the display screen is flush with the plate exterior, I’ll get a reading of the minimum clearance, Clarence.








23mm; Ok.


And the standoffs…




25.4mm… I’ll have to remove about 2mm of material.


I could use a grinder but like doing it old school – with a piece of Emory cloth. I have more control this way and can give myself a fairly decent manicure while I’m at it!




Using Emory cloth will allow for greater control of the amount of material removed while keeping the end flat.


After a few minutes of vigorous… errr… stroking…





Bingo! - now I just have to do the same for the other 5.



The next step is to drill the mounting holes. I’ll keep the vertical positions consistent with the PLED mount holes. Horizontally, the three sets of holes will be positioned to make the best contact with the existing TJ07 vertical structure – while not getting in the way of mounting hard drives. I don’t want to limit Daniel’s drive mount options or interfere with the location of the optical drive. A bit of measuring and figuring will do the trick. Once completed, I’ll drill the 6 mounting holes and then countersink them.




In case you’re wondering, the notch in the bottom left corner is to accommodate a threaded fitting in the corner of the midplate – you won’t see the notch when the piece is in place.






Next, I’ll install the standoffs.




The black “washer” looking thingies were provided by Nils. Because of having to countersink the screws, I needed something on the backside to offset the small portion at the base of the tapered screw head that came through the hole. Without them, the cylindrical offsets would contact the base of the screw head before the plate. These little fellas saved my bacon. (Thanks Nils!).




The PLED mount is pretty much done.



Now, I’ll move to the facade piece (not to be confused with codpiece). Since the angled edge is longer than needed, I’ll remove the excess material. The goal is to end up with the short, right angled section of the facade making flush contact with the outer edge of the existing TJ07 vertical structure.





I’ll overlap the facade with the TJ07 part and mark it for cutting.














Before cutting, honor must be paid to the lucky Zen Frog (I know, I know…).





After cutting and cleaning up with my bastard file…





Sweet success!


Next, I’ll secure the facade to the PLED mount by using 4 countersunk flat head M3 screws. They’ll be placed at the top and bottom and should be discreet when all is done. On the back of the PLED plate, I will epoxy 4 nylon locking nuts so that Daniel can remove the whole unit from the outside.












Once powder coated, the screws should blend nicely.


The next and final step is to line up the standoffs and attach them to the TJ07 vertical structure. I’ll use a paper template to transfer the standoff positions; then I’ll mark and drill the holes.




All 6 holes are drilled.



Wouldn’t you know it! My camera battery died just as I was going to take shots of it all together. Tune in tomorrow to see how it turned out!

Ok, that was cruel – I did manage to squeeze off one shot before it croaked – from the inside.






Thanks for looking in.

[dsecrieru]

Haha, that was cruel!

Awesome attention to details, Charles!

Daniel.