Cooler Master 840 ATCS Case Mod ..::D-9::..

[Bill Owen]

Hey gang, I've started the build for Cooler Master's media suite at 2010 CES. The D-9 concept was mine after seeing the movie.

I should know by first week of November what hardware CM will be sending me.




Conceptual drawing by E.E.L. Ambiense

Case Mods & Supplies used in this project by Mnpctech.com

Machined Aluminum Computer Case Feet Link



Acoustical Sound Proofing Sheets for your PC



Mnpctech is now stocking clear and colored sheets of cast acrylic for window mods

http://www.mnpctech.com/colored_acry...od_window.html



This is the Honeycomb Modders Meshwe used.



PC Cable management clamps
http://www.mnpctech.com/CableClamp.html


The canvas for this PC build is the Cooler Master 840 ATCS



Adding window to Cooler master 840 ATCS


Using tape roll to make curved corner


Make first initial cut with your Dremel and cutting wheel, to allow use of Jigsaw and cut the window more efficiently



You have created slot, this allows using a Jigsaw w/ 18 TPI cutting blade





Using a Jigsaw is much quicker than using a Dremel to cut your window


Use a rounded side file to debur the jagged edges of the new window





Notice the window location doesn't reveal the drive bays, this was intentional.

[Frananta]

Are you goin to watercooled it?

[Bill Owen]

I told CM that we should, the ball is on their court on what hardware will be used.

[Bill Owen]

Design that will be milled in the Cooler Master's 840's front bezel faceplate, Any remaining recessed portion for the 840's case badge will be filled in later with body filler before being painted.

[weston]

Design that will be milled

looks like the cnc did a great job!

[LogAn'sRun]

sweet, looks like a great start!!! Can't wait to see more as the film was awesome!

[Bill Owen]

sweet, looks like a great start!!! Can't wait to see more as the film was awesome!

I loved it too, thanks for tuning in!

[Bill Owen]

The 840's front plate

[Anemic]

Looks TOTALY awsome, you are very skilled!

[Lu(ky]

very nice bill Hey did you get yourself a laser cutting machine, or outside work? I need to find a place to do some work for me.. Can't wait to see the rest of this build..

[ShArKo]

Woww, that´s nice I want to see more..........

PS: How did you cut that front side??? with laser??

[HWaddict]

There are very skilled Pro's at Mnpctech!

[Dezmen]

Kickass case mod! I like D9 movie :P

[illidan]

omg! Bill how did you cut like that? finish is awesome?

[miptzi]

its impossible to be hand-made

awesome stuff!!!!

[BigJoe]

Very nice cut, especially on front panel

[EagleRock]

Great job with the front plate

[Bill Owen]

CNC. You can't achieve beveled edges with Laser

Upgrading the 840's stock 120mm exhaust fan to 140mm fan.

Cooler Master 840 ATCS rear 120mm exhaust


I'm holding up a 140mm Cooler Master fan over the stock 120mm grill. "Will it fit without anything obstructing it?"


The location of the 140mm fan resides along the crease on the back plate.


Making the initial cut with Rotary tool and reinforced cutting wheel before using Jigsaw


Using Jigsaw with 18 TPI metal cutting blade


Using rounded side hand file to clean up burrs along the edge of the cut.


140mm opening is cleaned up, next is drilling mounting holes for 140mm fan

[Arise]

Nice...i'll be here waiting for more pics of this mod

[dingdong555]

Awesome work Bill.

[Bill Owen]

Thank you! Now that we've got the 140mm hole finished, it's time to drill the 4, mounting holes for the fan.

My trusty center punch. I use this to mark where the holes will be drilled. Once the fan is positioned correctly, It's spring loaded, you push down firmly until the pointed ends "pops" and create a dimple for the drill bit. I insert this in each of the fan's mounting holes



The 140mm fan is located 7/8" from the top of the Motherboard tray.




vibration dampening fan grommets


Using a 1/4" size drill bit to make the mounting holes, this allows the fan grommets to fit.



Vibration dampening fan grommets installed.

[Bill Owen]

I really like the F-150 pick-up from District 9


For the exhaust fan grill, I cannibalized an early Monsta Rad grill prototype we made this year.

[railmeat]

wow...amazing man!

[Bill Owen]

wow...amazing man!

Thank you! Glad you like it railmeat

[Bill Owen]

I've cut the window from Lexan. It's tougher than plexiglass/acrylic, but 2 or 3 times more expensive. It won't shatter or crack "easily" You can buy Lexan sheets at Home Depot, Lowes and some hardware stores like Ace.

The window will be fastened with 1/4" socket head screws, for reinforced armour look

Using center punch to mark each fastener hole.



Roper Whitney No. 5 Jr Hand Punch kit available here
Hand punch (estimate $60 new)





"Look Ma, No deburring needed!"


The benefit of using Lexan is that you can drill or hand punch it without cracking it.



Clean hole cut! I love Lexan.





Ironically our concept drawing calls for bullet holes in the Lexan "bullet proof" window...lol