**** PHINIX NANO TOWER **** Smallest and most powerful mITX rig !!!

[phinix_mike]

I got some first photos!!! Its only aluminium pieces, but still!

These are main elements for frame structure (except bottom and middle panel).
You can see 4 rods, top panel and mobo tray....



Top panel has marked front space for dvd. Now you can see and get the idea how the slim dvd-rw will be mounted: on the front and vertically! I know.. crazy! But I have tested my slim dvd and it works perfectly in this position, so no worries.. If I didn't mention - it will be slim slot-in dvd, no tray.



Here's the mobo tray. Right now it has marked few elements, like CPU back hole matrix of small holes on the left and the position of mobo mount stand-offs. I took them from photo of DFI MI P55-T36 mobo
You can also see what parts I need to cut off on both sides at the bottom - this will make space for that 45 degree "cut-in rod spacer" I did to get mobo a bit deeper, as I showed previously on sketches...



Here are main rods... 20mm nice looking fellas.. two of them - "mobo holders" - will receive liposuction this weekend


Here you can see where Doctor Phinix will make first cut





That is for now.. it has been raining last few days.. I cannot go out to do some work and every time I go back home its dark already so cannot make nice photos...
This weekend I'm going to work a bit so will show some more progress.

[kgtiger]

When cutting thin sheet metal/aluminium, you need really fine teeth on the blade, so there are more teeth in contact with the cutting face at any one time.
As the material gets thicker, only for soft materials like aluminiam, perspex, hard rubber, plastic and so on.
You can decrease the amount of teeth on the blade just a bit and still have enough teeth in contact with the cutting face to stop the jigsaw from jumping around and grabing.
If the blades are blunt the jigsaw will also start jumping around and grabing and also if the speed is to fast or you push to hard.
You should try using different speeds, starting with the slowest at first, see how you go, if ok, then try a faster one, if not, move back.
Just take your time, theres no rush, it's the quality of the finnish your after.

Look forward to your next update, parts above look excellent.

[HDCHOPPER]

lock them all togather and use a fly cutter

Nice to see someone rolling thier own

[phinix_mike]

When cutting thin sheet metal/aluminium, you need really fine teeth on the blade, so there are more teeth in contact with the cutting face at any one time.
As the material gets thicker, only for soft materials like aluminiam, perspex, hard rubber, plastic and so on.
You can decrease the amount of teeth on the blade just a bit and still have enough teeth in contact with the cutting face to stop the jigsaw from jumping around and grabing.
If the blades are blunt the jigsaw will also start jumping around and grabing and also if the speed is to fast or you push to hard.
You should try using different speeds, starting with the slowest at first, see how you go, if ok, then try a faster one, if not, move back.
Just take your time, theres no rush, it's the quality of the finnish your after.

Look forward to your next update, parts above look excellent.

Thanks Tiger! I think I need to buy new jigsaw blade and try it out... I hope tomorrow will be a good day to mod

lock them all togather and use a fly cutter

Nice to see someone rolling thier own

Thanks Chopper! Nice to see you here - I see you are not sitting only on OCZ forum

[phinix_mike]

Well, during this weekend it was raining all the time, so couldn't work outside. Worked in the attic a bit. I prepared and cut mobo tray and bottom panel, also sanded them nicely to have clean shiny edges.
After that I started with that two rods that keep mobo tray. As I mentioned above I wanted to thinner them a bit to push mobo tray a bid deeper, 5mm into those rods. So I took my trusty dremel to try it out.. During half an hour I managed to brake 2 reinforced cutting wheels and get 3mm deep cut... So I took my badass jigsaw with special metal cutting blades.. After another 10 minutes I get another 2-3mm deeper... Of course my special blade was worn to the frame So decided to drill holes along that cut line I drew on the side of that rod, so it will take some material off so jigsaw cutting would be easier. I drilled about 10 3mm holes and my drill press stopped when drill bit was in about half way down...
So I went to B&Q and bought 5 new mega-special thick-metal cutting blades... After another 2 hours I managed to get 2 of new blades totally worn.. and got 2cm cut... So after whole afternoon trying to cut this rod I decided these rods are going to cnc place Now I'm really convinced that I bought some kind of super-hard grade aluminium rods

I think I'm gonna have to add one more detail in description of my new build - it will be bulletproof

I hope I'll get those rods back till Firday and then all good stuff gonna start.

What I need to do this weekend is:

• drill and tap all 4 rods at the bottom and top
• create main frame - measure against rod holes and drill bottom and top panel and screw them together
• drill and tap hole in "flattened" parts fo rear rods for mobo tray
• drill and fit in mobo tray to rear rods
• cut the middle sqaure hole in top panel
• measure and cut 6 support L-shape corners for bottom and middle panels then mount them
• fit in middle panel
  

Looks lie a lot of work, but it will be much easier when rear rods will be ready. That sounds fun for me this weekend!:blush: I hope you guys gonna like it as well...

[Waterlogged]

Well, during this weekend it was raining all the time, so couldn't work outside. Worked in the attic a bit. I prepared and cut mobo tray and bottom panel, also sanded them nicely to have clean shiny edges.
After that I started with that two rods that keep mobo tray. As I mentioned above I wanted to thinner them a bit to push mobo tray a bid deeper, 5mm into those rods. So I took my trusty dremel to try it out.. During half an hour I managed to brake 2 reinforced cutting wheels and get 3mm deep cut... So I took my badass jigsaw with special metal cutting blades.. After another 10 minutes I get another 2-3mm deeper... Of course my special blade was worn to the frame So decided to drill holes along that cut line I drew on the side of that rod, so it will take some material off so jigsaw cutting would be easier. I drilled about 10 3mm holes and my drill press stopped when drill bit was in about half way down...
So I went to B&Q and bought 5 new mega-special thick-metal cutting blades... After another 2 hours I managed to get 2 of new blades totally worn.. and got 2cm cut... So after whole afternoon trying to cut this rod I decided these rods are going to cnc place Now I'm really convinced that I bought some kind of super-hard grade aluminium rods

I think I'm gonna have to add one more detail in description of my new build - it will be bulletproof

I hope I'll get those rods back till Firday and then all good stuff gonna start.

What I need to do this weekend is:

• drill and tap all 4 rods at the bottom and top
• create main frame - measure against rod holes and drill bottom and top panel and screw them together
• drill and tap hole in "flattened" parts fo rear rods for mobo tray
• drill and fit in mobo tray to rear rods
• cut the middle sqaure hole in top panel
• measure and cut 6 support L-shape corners for bottom and middle panels then mount them
• fit in middle panel
  

Looks lie a lot of work, but it will be much easier when rear rods will be ready. That sounds fun for me this weekend!:blush: I hope you guys gonna like it as well...

If your burning through blades/bits/cutters while getting nowhere, it means your using the wrong speed and/or feed, this goes for any tool. What jigsaw, and how many SPM are you roughly using?

[phinix_mike]

If your burning through blades/bits/cutters while getting nowhere, it means your using the wrong speed and/or feed, this goes for any tool. What jigsaw, and how many SPM are you roughly using?

P&P jigsaw.. thing is I tried slow, medium and fast speed... some where fine and didnt jump, but didnt cut either...
Thing is there was no blade for full metal 20mm thickness. Maximum there was in shop was <30mm but alu profile.. empty square rod... Dremel took ages to make a 3mm deep cut so I had no time and wheels to do 173mm cuts 4 times (two rods, both sides). I ended up having one rod looking like a battlefield
Anyway, rods are away to cnc place. Should get them back before weekend

[kgtiger]

Aluminium is a different creature than steel and extruded ali is different again, a tad harder than rolled sheet.
Sorry you had no luck getting the job done, at least having them cut at the CNC place they will be perfect.

[Neox69]

Wow, interesting... Subscribed!

[Laine]

If you use L-profiles instead of the solid rods, you would probably earn the extra 35mm and be able to fit the radiator internally if you want, plus it would save you some weight.

But your build, your call.
I'm sure it'll end up superb either way.

[phinix_mike]

Aluminium is a different creature than steel and extruded ali is different again, a tad harder than rolled sheet.
Sorry you had no luch getting the job done, at least having them cut at the CNC place they will be perfect.

You know how it is sometimes - you cannot do everything by yourself.
I may be able to do it, but it would take me weeks, cause I don't work on my project everyday, weekends most of the time, so it would be very long before I cut them myself and then file and polish them. CNC will make perfect lines, so I will just add some finish (polish, angle corner) to it and I can go with other things.

Wow, interesting... Subscribed!

Thanks!

If you use L-profiles instead of the solid rods, you would probably earn the extra 35mm and be able to fit the radiator internally if you want, plus it would save you some weight.

But your build, your call.
I'm sure it'll end up superb either way.

Thanks!

Yes, I could use them to keep main panels, but I didn't want to do it like that - I wanted to make some hard-ass stable frame first My first build - the Cube - didnt have frame, so yes, it saved some space. But this one is exactly like I wanted. This external radiator is a part of design - I loved it so much in MNPCTECH Bill's modded case, that I decided to make one for me. This is thin radiator, 35mm so it wont stick out so much... Plus it will be on the back of the case, plus keeping it outside will keep the heat from it out - that was also a plan...

[phinix_mike]

Guys, I feel it in my bones that this weekend will be huge! Upcoming update will overwhelm you all! Well.. I hope I may receive back my rods, also some goodies coming up, have few packages to pick up in post office - cannot do it now cause Royal Mail gave silly hours to pick packages by yourself - 8-12 in the morning, so I will be picking them all up on Saturday. I will work my ass off to finish main frame and show it on log of course!

However before that update I will show you some sketches of few parts I've planned.

I have also received support from major companies, but that has to stay a secret for a while Don't worry - I will tell and show everything in right time! :thumb:

(oooh, I love to tease you !!! )

So guys, this weekend will bring major update in this project and will put some more light on my project. You will learn how I'm going to mount things in this little monster and will see how this magic happens I know it is long time to wait, believe me - I cant stand waiting for weekends too.. It is sooo hard for me, but right now weekends are the only time I can work on my sweet rig.

As always... STAY TUNED !!!

[kgtiger]

Good to hear your excitement about your new jig, projects like this seem to take forever to just get off the ground.
Looking forward to see the next update and finding out about your secret and congratulations on receiving support as well.

[phinix_mike]

Good to hear your excitement about your new jig, projects like this seem to take forever to just get off the ground.
Looking forward to see the next update and finding out about your secret and congratulations on receiving support as well.

Thanks man! I really didn't expected to receive so many support from companies! It was my wish to get attention and it actually happened! I will do my best to make this project worth of getting all those goods...
Its Friday! Tonight I'll be chillin a bit before tomorrows work. There is package coming with those rods, fixed on CNC so that means I'll be ok to continue my work. Weather seems to be better and forcast says it will be chilly this weekend, even maybe some snow!

[kgtiger]

Snow, I am looking at a week of high 20s-low 30c degrees, have fun making snow men/women.

[phinix_mike]

Snow, I am looking at a week of high 20s-low 30c degrees, have fun making snow men/women.

I wish I could move to Australia! However all those spiders, crocodiles... not sure about that..
But you got snow as well! Depends where you live, but if you live east side, you can get all weathers there

My priority is Canada, second is Australia

[phinix_mike]

Guys, hardware update today!

I went to post office and picked up two packages.
So guess what I have received?????

Bill from MNPCTECH sent me modding items, which will add special look to my Tower:

1) BILLET MACHINED ALUMINUM CASE FEET



2) Modder's round-hole mesh



3) Black anodised M4 Thread x 30mm Length (1-3/16") Stainless Socket Cap Screw Sets for rear radiator fans



4) Black anodised M4 Thread x 16mm Length (5/8") Stainless Socket Cap Screw Sets for fastening outside panels



5) Fan grommets




Bill, again - huuuuuuge thanks for your help !!!!!!!!!!!

[phinix_mike]

Second package came from Joan from CRUCIAL !!!

When opened the envelope I saw these!



These memory sticks will be PERFECT for my Tower! Imagine when they gonna light up inside, giving nice shine on all internal parts with those leds!
These are DDR3 - my previous Tracers were DDR2, which had shorter rows of those leds. These new DDR3 have leds on whole length of the sticks!
Now I need to wait for mobo and will show you guys how those Tracers look like when I test hardware!

Again, huuuuge thanks come to Joan from CRUCIAL UK !!!!

[Vinas]

What do you mean what about it?
You want to know where the cables will go?
You will have to wait for it a bit longer

Oh the suspense I can barley handle it!!!

Keep coming with the updates please!! I can't wait to see it take shape.

[Bill Owen]

Congrats! can't wait for the next update phinix

[phinix_mike]

Thanks Bill! Yep, tomorrow will be new update! I'll show some latest moves tomorrow night, so your time it should be afternoon

[kgtiger]

Good stuff there mate, nice to see these companies getting behind people that have the guts to step out and try something different and new, nice one.

[phinix_mike]

Thanks tiger! I'm getting so many things now, I'm so happy cause this kind of help gives me opportunity to do what I really would like to create without any compromises!

Anyway... After few threading (tapping) attempts I decided to use something stronger - right angle (cross) dowels.



I couldn't easily tap those holes in aluminium rods, so I went to B&Q and bought these dowels.
They are perfect for this job - so strong, holding bottom panel firmly and securely.
I will also use them to mount top panel. I just love them! Truth is, it takes amount of time to install them - because they are 10mm thick and 12mm long (M6 holes), first I had to drill long hole in bottom of the rod for screw (6mm bit), then across that hole another one for dowel - there had to drill twice, once with small 6mm to make drilling with big drill a bit easier; then last drill with 10mm thick bit. Its easy to count - 4 rods, 2 holes each, 3 drills per side - gives 24 drills
Changing drill bits all the time, clamping rods... now I feel like putting my hands in pile of ice wouldn't be a bad idea...

After my previous build - the Cube - now I can say - aluminium is a PAIN!!!!

Photos tomorrow, I'm so tired my hands are full of pain after few hours of trying to tap those rods and then all the drilling...
However - weekends mission accomplished ! I'm looking on standing frame!!! You guys need to wait for photos til tomorrow

Let the Dremel be with you !!!

[phinix_mike]

NEW UPDATE (30/11/09)

This time - real thing! I worked on main frame this weekend and today.
Having some problems with tapping those rods on Saturday, I decided to go with some more powerful stuff - those dowels I mentioned in previous post. It took a lot of drilling, with hand drill and drill press. Biggest drill I used, 10mm one, made a lot of noise!
My attic looks like it has aluminium carpet now Seriously! I have to hover before my wife's gonna see it...

Here are all the photos, please have in mind this is rough aluminium, still needs some sanding on edges and polishing. After all it will be powder coated so it will look like fabric made!:thumb:

Just a quick show off - I bought some nice piece of equipment yesterday. Was going for 14.4V Bosch, but I found great deal on 18V Hammer Black&Decker




As mentioned in build description in first post, I'm going to use new Akasa Apache 120mm fan, which supposed to be the best with H50 cooler. So I bought it when found nice weekend deal and price went down from £15 to £9 last weekend













Looks ugly as hell! I believe the person who designed the colors for it will be working late this Christmas! Apart of that it isn't silent, like I read on some forums, but it is very very quiet. AND it blows... blows loads of air! When turned it on my face it felt like hair-dryer! I mean it! Pretty powerful stuff.

Now, lets get back to business, shall we?

Here it is: these are cut off corners on mobo tray. All filled as you can see, will need some sanding and polishing at the end..





Also drilled holes for mounting screws. It will be screwed to the rear rods with short M4 bolts.



Here's a quick shot of flattened rod:



Here is how I worked out mounting rear and top panels to rods. Cross dowels Ladies and Gentlemen.. Cross dowels...





So we have smaller, 6mm hole for screw at the bottom of the rod, second one is bigger 10mm hole for dowel. All lined up and drilled.. pretty cool, professional looking thingy, also VERY strong!



Here is bottom panel screwed with those dowels:



...aaaand all four rods, sticking out like a.... like sticking out rods..... :blush:



Then top panel, with cut off long rectangle for front mounting slim dvd. It will be done later, when the mobo will be mounted. Before that I cannot line up the drive-tray.



Top panel screwed to the rods. Some holes still need to be lined up a bit and their egdes a bit polishes. Some screws didnt get to the panel surface easily, some rough aluminium bits are still there...



Looks cool...



...AND the whole thing!!!







Now.. I used some duct tape to hold mobo-tray... forgive me that cheap move, but I haven't drill those screw holes in rods yet to mount that tray properly.. It will be done during the week...



You can see that small 3mm gap above mobo-tray - that is the place where middle panel will be pushed in...



Tower itself...





For size comparison - Akasa 120mm fan box sticked inside ...



...and on top...



...and 2L Coke bottle inside the Tower... I told you it will be water-cooled after all!




OK. So this is the big update from last weekend. I hope you liked it. See, even sun was out today!
Now I'm going to spend some time on polishing edges finishing holes and mounting mobo-tray. After that will mount middle panel with those right angle support alu shapes.

So...

STAY TUNED !!!!

[kgtiger]

Excellent work there phinix_mike, the milling work, wored out well and its all comming together.
If you want to remove the bur around the holes you have drilled, then just use a drill bit,
say 2 sizes bigger and just push slowly into the hole while on slow speed to remove that bur.
You will only need to go down .5mm, just below the surface.

Those dowels are a nice way around tapping the threads out.
If you think aluminium sucks to drill you should try bisalloy 360, it rounds of the tip of your center punch in 3 hits.