09/10 Project

[alphadog009]

you are setting the bar too high!!!!!!! i seriously cant imagine a build rivaling this one in terms of handmade parts with the amount of perfection and precision that yours have
keep it up and hope your finger feels fine!

[marxviper]

nice work, love the workshop

make sure you take care of your fingers. every single one of them count.

[rjkoneill]

this is just excellent. so many inspiring ideas.

the attention to detail is incredible, and your photography shows the progress wonderfully

[callen_1]

This build is very inspirational to say the least.

Cheers, S3RV0. I appreciate it mate

Inspirational stuff callen

oh and How long are those 5870's ? 'cause naked pcb is shorter than with the aircooler

Thanks, Oli4v. the cards are a fraction under 285mm or 11 and 1/8" long when installed in the case. They were measured from the backplate

you are setting the bar too high!!!!!!! i seriously cant imagine a build rivaling this one in terms of handmade parts with the amount of perfection and precision that yours have
keep it up and hope your finger feels fine!

Fingers feeling all better now but thanks for the concern, alphadog009 .

As far as the build goes, i may hand-make a lot of stuff, but there are so many builds that make better use of the pre-mad/bought parts. I just have a lot of fun doing it

Thanks for the kind words, mate

nice work, love the workshop

make sure you take care of your fingers. every single one of them count.

cheers, marxviper. and i'll be careful from now on (i learned my lesson )

this is just excellent. so many inspiring ideas.

the attention to detail is incredible, and your photography shows the progress wonderfully

Awesome complement, rjkoneill! I'm really glad you think so



I have another update so i'll post soon

[callen_1]

Hi everyone. I did some more work so i'm ready to share a little. I hope you like


First I secured the covers to the acrylic slots. I've been meaning to do this for a while but always managed to find something else to do.
Drilling, countersinking and tapping is booooooaring!! I had to do it 35 times.... I'm really glad its over .


So after taping i marked and drilled guide holes with a 1.5mm drill bit -








Each acrylic slot has to go in a certain place for a perfect fit. while each slot probably fits in another slot's position, it won't be perfectly
straight. There are 7 individual slots plus a top piece, so if i jumble them there's almost endless combinations, and i can't be bothered
installing and removing slots millions of times! This also applies to the covers i just drilled.

Anyway, getting to the point, the slots and covers needed to be numbered. The problem was the ink would keep running whenever the
part got tapping fluid on it, so i used a soldering iron and engraving tool for a more permanent solution (i should have just said that in
the first place, sorry ) -








After that everything was drilled through, tapped, countersunk, and screwed (yeah, i screwed my pc.... so what? ) -








Tubing is going to pass horizontally through the centre of one acrylic slot (#5 to be exact). This left the acrylic held together by a very
thin edge (the edge which you see from inside the case, Pictures below should help). The first time i made the fifth slot it was too weak
and snapped along the edge, so this time i came up with a better solution.

When i had the acrylic re-cut at the laser cutters i asked them to leave small bridge-like extensions across the middle. All that was left to
do was boar out enough so the tubing could pass through but leave enough to give the slot more strength -





First try (too hard) -




Second try (too rough) -




Third try (just right) -









And a shot of everything in place -






The next thing i worked on was the bottom of the feet.


I wanted the middle of the foot (on the bottom) bored out a little so when i installed the rubber it would be mostly hidden. I wont stick in
the rubber until i decide what sort of finish i want on the feet though -










See, i really do work sometimes -






Lastly, i did a bunch of work on the power and reset buttons.


I started by re-making the acrylic -






I then re-made the shafts that held the button to the bracket. I moved from aluminum to steel, made the shafts narrower, and used 4 for
each button instead of 2. All of this greatly helps reduce movement of the button and helps hold it in place -








I used a set of calipers to measure where the thread needed to stop and where the shaft needed to be cut. It was then marked with the
threading tool, which was also used to turn the end down a little and lastly make the thread -










This is my thread tester. It lets me know if i need to make the thread deeper -








Once the thread was right, the easiest way to part it is with a hacksaw then spin it around and face the hacked end -












Now, just do that 7 more excruciating times! -






With the buttons taped in place and marked, i made guide holes with a 1.5mm drill bit. It was then drilled through with a 2.5mm bit and
the buttons were tapped -








Now for something a little different. I had a lot of trouble finding springs which were the right height, size and tension. So, after a bit of
research, i found out it's actually really easy to make your own; especially on a lathe -


To start, i needed a tool/jig to help keep the spring wire tension tight while winding. It would also be used to keep the coils set at a
certain distance apart (BTW i didn't come up with any of this myself, it was in the guide i found on the net). It was also at this point that i
found out how strong High Speed Steel (HSS) was!

I tried to use one of the HSS tool blanks to make the jig first. I normally grind these blanks to make new cutting tools, but they were the
right size to fit the tool post and i thought i'd give it a try -







It didn't even scratch the blank and almost broke my drill bit! Crazy hard stuff to be sure!


So i moved onto some aluminum square bar next and used a grinding wheel to cut it to size then drilled out a hole -








The springs i'm making didn't need too much tension. The original springs i bought and used were waaaaaay too tight and i ended up
screwing up the first set of buttons because of them :angry:. This time i wasn't going to make the same mistake and bought a few
different sized guitar strings to try which i would use as spring wire (#17 was just right)-








Here's a quick run through of what's happening in the pics below; first i found a nail which was about 3mm in diameter. I stuck the nail
and the tip of the guitar string in the lathe chuck and put the jig i made in the tool post. Starting the lathe very slowly in reverse, i let the
wire wind around the nail in a tight coil while holding the loose wire firmly in the jig. i had pre set the gears in the lathe for 1.25mm
thread cutting, so when i turned the lever to engage the lead screw the jig would move back 1.25mm every turn of the chuck. After a
few turns i disengaged the lead screw and let the coil tighten again. Lastly I cut the spring and used a grinder to grind each end flat.
Rinse and repeat -
















Anyway, moving on -










Evened it up on some sand paper -
























Sorry for dragging this out for so long but i'm almost there


The steel pieces in the following pics weren't attached together so i fixtesized it -














I made 1 more weld to be safe -












After a sand i'm left with this -
















Once the bracket is screwed down, the LEDs installed, and the steel covers are stuck in the correct position (they're resting on the case
in the pic below) there will be a blue ring around the edge of the cover and the power/reset symbol will illuminate (i still need to file
away some more steel though). I still don't know whether to plug the hdd led into the reset button so i can see drive activity but i'll work
that out later. Next update i'll also install a momentary switch so they actually work -





That's all for now guys ,

Thanks for taking a look,

Callen


P.S. have an awesome weekend

[ScottALot]

Custom power buttons? You're not going the extra mile, you're going the extra light year

[MegadetHCl]

Yeah, no kidding! According to the last pic, even his new Reset button will have a Low, Medium, and High settings!

[h20xide]

cut

with making the threads for the nails, did you set the LATHE to do it automatically? like those auto cuts, you just do it once and it mimics you

I know the ones Ive used had that feature and it was great, could route the out of anything and be precise as ever without having to touch the machine (except when needing to slide it back to the right)

also, why use a saw to cut them off? there is a LATHE bit for that

really impressed with the custom buttons, supurb attention to detail mate

[Armitage]

I had trouble getting my supplied power buttons to function >.<!

Btw - What kind of planning went into this ? Cad design etc?

[callen_1]

Custom power buttons? You're not going the extra mile, you're going the extra light year

i just get funny ideas sometime. Then i try to work out if it's possible to make them with the tools i have, and have a crack at it. The buttons are probably a little over the top but it's just so fun making stuff (and i get points for originality)

Yeah, no kidding! According to the last pic, even his new Reset button will have a Low, Medium, and High settings!

hehe good spotting

with making the threads for the nails, did you set the router to do it automatically? like those auto cuts, you just do it once and it mimics you

I know the ones Ive used had that feature and it was great, could route the out of anything and be precise as ever without having to touch the machine (except when needing to slide it back to the right)

also, why use a saw to cut them off? there is a router bit for that

really impressed with the custom buttons, supurb attention to detail mate

Thanks, h20xide.

I think you mean lathe instead of router . There's no auto cut/copy feature on this lathe unfortunately, so each one was done manually. It took quite a long time to get them just right, and by quite a long time i mean F#$%ing ages!!

Your right about the bit to cut off the piece, it's called a parting tool. The problem is, when the diameter of the piece your turning gets very small (like the little pieces i was turning above) the edge which the tool cuts is turning much slower, even if the lathe is set to max speed. Unless your lathe is super rigid, the tool gets pulled down instead of cutting into the metal. This can mess up the tool or screw up the piece your turning. It's actually pretty common practice to use a hacksaw to cut the last bit, i did the same with the feet too.

Anyway, that's time for your session today. I'll post the bill in the mail

I had trouble getting my supplied power buttons to function >.<!

Btw - What kind of planning went into this ? Cad design etc?

Hey, Armitage. I drew the button covers in CAD if that's what you mean? The 2 pieces for each button were then cut at the laser cutters. All the acrylic and lathe work was just thought up as i went along, they're pretty simple really when you look at them.

[Dahaka]

This thread, complete thread, every single post are a masterpiece but... a REAL MASTERPIECE!!, is so (i)ng awesome your workshop, your case and your config, is deserve it to send it to hall of fame of all threads on history of humanity.

Regards from Chile!.

[ohms]

God damn Callen, now thats Xtreme! Making your own power and reset buttons. For a while when I saw it in the earlier stages I thought you were putting shocks on what was to be the wheel base, and then the cross bar would attach to the bottom of the case.

All I could think was "wow, shocks for the wheels on the bottom of the case, what else will he think of!"

The buttons came out awesome looking, the blue was definitely a nice touch. It looks so sharp and the blue helps to break up all the clear plexi and give it more flavor and attitude. The use of the guitar strings to make the springs was a brilliant idea.

You should make power/reset buttons and video card stand ups and sell them Callen Brand!

[aka_GK]

yeah, tiny update as usual
good job callen, <3 this buttons

[SovietKitsch]

This mod is just unbelievable.

[Wezly]

[CptDreadFlint]

Main man Callen! You single handedly reinspire me to shake off the tired Vegas dust and hop back aboard the mod ship.
Still not altogether clear with where you're going with the 7 acrylic slot situation yet, but it looks crazy GORGEOUS.

The use of guitar strings for your power and reset button springs blew my face clean off.

Now if you'll excuse me while I go look for my face thank you very much.

Incidentally, if you wont be using the 10 or 14 guage strings, send it to me. I've got a couple of guitars in need of restringing .

[Red-5]

Always a pleasure to read your posts and see the amazing work in the pics. Each new update always has something to amaze me in it.
Your skills are second to none and those switches are just stunning mate. I'll stop gushing now Lol.
Looking forward to seeing more.

[Oli4v]

Extreme precision !

and thx on the info on the cards, gonna get myself a set of those this summer too

[kwscore]

Custom power buttons

Great work

[y0gi]

You're quite the freak, my friend. Hats off.

[tool_462]

You...made your own...springs? Probably the most epic build I've ever seen.

[shazza]

Next thing we know, you'll be making your own Aluminum Alloys ...

Dang, I'm pretty lost as to where you're going with all of this, but loving the ride (that's not a complaint or criticism). You are doing stuff that would never even occur to most of us.

[callen_1]

This thread, complete thread, every single post are a masterpiece but... a REAL MASTERPIECE!!, is so (i)ng awesome your workshop, your case and your config, is deserve it to send it to hall of fame of all threads on history of humanity.

Regards from Chile!.

Thanks, Chile . i lol'd at "hall of fame of all threads on history of humanity", is there really such a thing

God damn Callen, now thats Xtreme! Making your own power and reset buttons. For a while when I saw it in the earlier stages I thought you were putting shocks on what was to be the wheel base, and then the cross bar would attach to the bottom of the case.

All I could think was "wow, shocks for the wheels on the bottom of the case, what else will he think of!"

The buttons came out awesome looking, the blue was definitely a nice touch. It looks so sharp and the blue helps to break up all the clear plexi and give it more flavor and attitude. The use of the guitar strings to make the springs was a brilliant idea.

You should make power/reset buttons and video card stand ups and sell them Callen Brand!

No shocks i'm afraid, Ohms. I think Darth Beavis is doing something along those lines though? I'm glad you like the buttons too, but they take waaaay too long to to sell

yeah, tiny update as usual
good job callen, <3 this buttons

haha yeah, it was a small one wasn't it . Cheers, man.

This mod is just unbelievable.

Thanks, SovietKitsch. I appreciate it, mate

Main man Callen! You single handedly reinspire me to shake off the tired Vegas dust and hop back aboard the mod ship.
Still not altogether clear with where you're going with the 7 acrylic slot situation yet, but it looks crazy GORGEOUS.

The use of guitar strings for your power and reset button springs blew my face clean off.

Now if you'll excuse me while I go look for my face thank you very much.

Incidentally, if you wont be using the 10 or 14 guage strings, send it to me. I've got a couple of guitars in need of restringing .

lol at blew your face off :p. I hope that image i sent you helped clear the confusion about the 7 slots.

Now get your ass back in the workshop. As your biggest fan i demand results dammit!!

Always a pleasure to read your posts and see the amazing work in the pics. Each new update always has something to amaze me in it.
Your skills are second to none and those switches are just stunning mate. I'll stop gushing now Lol.
Looking forward to seeing more.

No, please, gush away haha. I really appreciate the kind words, Red

Extreme precision !

and thx on the info on the cards, gonna get myself a set of those this summer too

No worries, Oli4v . I hope i can actually use my cards this summer

Custom power buttons

Great work

Cheers, mate

You're quite the freak, my friend. Hats off.

I am a bit of a freak, just not in a good way . Thanks, y0gi

You...made your own...springs? Probably the most epic build I've ever seen.

Thanks, bud . But there are many, MANY crazier builds in this forum! That i'm sure of

Next thing we know, you'll be making your own Aluminum Alloys ...

Dang, I'm pretty lost as to where you're going with all of this, but loving the ride (that's not a complaint or criticism). You are doing stuff that would never even occur to most of us.

haha that's not a bad idea , maybe there's a guide on google for that? :p

I get confused sometimes when people say they're lost where i'm going with this. Then i realise i never once explained what i have planned, so i don't blame you . You'll just have to continue relaxing on you luxury cruiser and keep on guessing muahahaha

[Wezly]

space ship.

[The_Gnu]

beuatifull update.. love your work