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Project: Aluminum Water Cooling Case

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This is a project/build log for an aluminum case designed specifically for a large water cooled rig, specifically:
  • 3 x 140x4 radiators
  • 1 140x3 radiator
  • 10-slot motherboard tray







Stay tuned!
 

t_ski

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In the for the first sub :toast:
 
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The basic frame of the case is done, which consists of .5x1-inch u-channel with its ends plugged with blocks (pictured in the first post), press-fitted and pinned with a #4 screw along with some 1-inch angle:










The assembled case frame is too tall to fit in the camera frame. hehe





The frame looks kind'a "meh" until I bolt on the gorgeous anodized quarter rounds.




 

Funtoss

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How much did all these cost you!?
it looks so nice!
 

Eric_On_Web

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Depends where you live Funtoss. You are in New Zealand and hes in USA. For my part I am in Quebec one of the largest aluminum producer in the world so even cheaper here. Seek around in New Zealand if there's a big aluminum importer from China or producer in your country. Just saying..like a world economy class at the same time. hehehe
 
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The two shelves were cut from a .10-inch thick 5052 via my trusty router, a straight edge and a downcut spiral bit.




At the back corners of the shelves, two .5x1-inch cutouts were routed out via a temporary router jig.






The rounded inside corner left by the .5-inch flush router bit were filed square.




FWIW, here's the difference in the thickness of the aluminum sheeting I use compared to everyone else.




Finally, a mockup of the shelf inside the frame of the case:

 
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that is just awsome. I want one!
 

Cold Storm

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sub to watch it all unfold. Thanks for the project.

:toast:
 
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Subbed.

That is one huge case.

3 x 140x4 + 1 x 140x3 = 3ft² of radiators.

Huge.
 
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That thing will be solid!! Love it :)
 
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The 5.25-inch drive bay rails finally came back from a local fabricator.




And a 140x4 rad arrived in the shop.



 

Wile E

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Hmmm, subbed.
 

>>PhoeniX<<

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Subbed :) Looks great
 

Blue-Tiger

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Subbed, the model looks soo clean! :D
 
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Next up is to cut the front sheet.




In order to cut-out all of the openings for the 5.25-inch drives accurately, a custom router template is required. I used .5x1-inch u-channel and .25x1.25-inch flat bar to frame the openings on .5-inch particle board.




The aluminum bits guided my flush trimming router bit.




The aluminum bits were removed and the particle board template was used to cut the .10-inch thick aluminum sheet.






Now I just need to square all of the corners and cut to width. Ugh.
 
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Another huge case. That is one big radiator you've got there.
 
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subd! this guys projects r EPIC!!! :respect::respect:
 
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Subbed, this looks good. :)
 
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Motherboard 990FX-UD5 / GA-MA785GPMT-US2H
Cooling XSPC - 240rad 480rad 5 x 120mm out, 6 x 80mm in / H220-edge 1/2" & 2 x 120mm Magma
Memory 4gb PI 6,8,6,18 1T 1706mhz / 4gb Crucial D9's 1400 @ 6,6,6,18,1T
Video Card(s) 3gb HD7950 / Onboard
Storage 2 x 120gb Sandisk ultra plus 2tb WD / 60gb vertex 2 + 2 x 2tb WD Greens
Display(s) 3x24in Dell Ultra (portrait) / NEC 32" FullHD LCD
Case LL PC71A Full tower / Antec fusion black with Imon remote Modded for WC
Audio Device(s) OB / Auzentech cinema 7.1
Power Supply TT 700w TR2 / TT 600w Litepower modded with Noctua S12 fan.
Software 7 Ult / 7 premium x64
more?? pleease!! Loving the fabrication on this project. :)
 
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"Life" had gotten in the way of this project for a few weeks, but I've managed to fabricate the inner and outer sheets of the front panel. It took me 5 hours to square-off all of the inside corners.

 

HammerON

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Benchmark Scores Always changing~
Sub'd. Glad to see you building another monster case!
 

Wile E

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