Project: Aluminum Water Cooling Case - Page 4

t_ski · Apr 17, 2012, 03:01 AM

Glad to see you're still going with this, but I'd love to see it come along a little faster

adulaamin · Apr 17, 2012, 03:05 AM

Man I wish I had the resources and skills to do what you do... AWESOME job so far... Can't wait to see it finished...

Spotswood · May 7, 2012, 03:14 AM

I made a mistake, placing the false back too far into the case, which required having to re-fabricate the back sheet. But I figured I could take advantage of the situation by improving the mounting of the motherboard tray, by fastening the tray to the false back with a 7/8-inch long spacer.

I don't remember if I already offered this tip before, but I try to reduce the wear and tear on my 1/2-inch flush cutting router bit by first rough cutting with a 3/16-inch spiral downward cutting bit.

johnnyfiive · May 7, 2012, 03:33 AM

Whoa, awesome progress! This thing is going to look awesome!

Spotswood · May 28, 2012, 03:34 AM

A PSU mounting plate was routed out of a piece .10-inch thick aluminum sheet with the help of a custom template.

In order to accurately transfer the locations of the PSU mounting holes, threaded hole transfer punches (mcmaster.com part # 3385A31) were threaded into a PSU.

And then the PSU was carefully centered and pressed into the sheeting, with the end result being a perfect squarely mounted PSU.

Phusius · May 28, 2012, 03:36 AM

faster! faster! ::cracks whip::

thats what she said

de.das.dude · May 28, 2012, 06:48 AM

Quote:

Originally Posted by Spotswood

A PSU mounting plate was routed out of a piece .10-inch thick aluminum sheet with the help of a custom template.

In order to accurately transfer the locations of the PSU mounting holes, threaded hole transfer punches (mcmaster.com part # 3385A31) were threaded into a PSU.

http://i715.photobucket.com/albums/w...ferPunches.jpg

http://i715.photobucket.com/albums/w...PunchInPSU.jpg

And then the PSU was carefully centered and pressed into the sheeting, with the end result being a perfect squarely mounted PSU.

http://i715.photobucket.com/albums/w...ntingPlate.jpg

thats a nifty piece of tool right there :O

t_ski · May 29, 2012, 12:43 AM

Quote:

Originally Posted by Phusius

faster! faster! ::cracks whip::

Agreed. Spotswood, your builds are awesome, but they take just too damn long

Spotswood · Jun 4, 2012, 03:08 AM

Another router template was made to cutout the areas for the PSUs out of the back sheet. A guide was clamped to the bottom of the template to keep the cutouts perfectly aligned along the bottom.

Spotswood · Aug 19, 2012, 12:43 AM

Turned out that I needed to cut one more slot out of the bottom shelf. But the last time I used my wooden "small slot" router template, I somehow managed to crush one edge, so I quickly cobbled together a new out of some left over t-slot extrusion. I'm really loving using these t-slot extrusions to make router templates - fast and accurate!

Here's a teeth-shattering video of me cutting out the slot.

Spotswood · Sep 10, 2012, 01:15 AM

Performed the mind-numbing task of fastening the bottom and top sheets to the case frame via flat head socket cap screws. Through and countersink holes were drilled into the sheet and transferred to the case frame via a self-centering counterbore drill bit.

Bottom sheet all fastened:

And top sheet all drilled out:

mediasorcerer · Sep 10, 2012, 01:44 AM

What a monster, pleasing to see your metalwork, inspiring and thanx! How will you finish the aluminium? what about anodizing in a color??

Spotswood · Sep 10, 2012, 01:52 AM

Quote:

Originally Posted by mediasorcerer

What a monster, pleasing to see your metalwork, inspiring and thanx! How will you finish the aluminium? what about anodizing in a color??

Thanks. Current thinking is for a black powdercoat finish.

mediasorcerer · Sep 10, 2012, 01:57 AM

I used to do casting in aluminium, it can look great polished, but does oxidise slightly over time, black powdercoat sounds beautiful. cant wait to see it!

Spotswood · Nov 5, 2012, 03:58 AM

Drilled out the holes for the vandal resistant switches and fastened the front sheeting to the case.

HammerON · Nov 5, 2012, 04:01 AM

Long time no see

Glad to see you are making progress

de.das.dude · Nov 6, 2012, 12:36 PM

i thought you had forgotten us XD

Spotswood · Nov 21, 2012, 03:09 AM

Finished the lower portion of the back sheet, which involved installing the PEM nuts, trimming the PSU mounting plates to the final size and creating an extra solid cover plate (which I almost forgot to do).

adulaamin · Nov 21, 2012, 04:20 AM

I am in AWE...

Keep it coming... Keep it coming...

Apr 17, 2012, 03:01 AM	#76
t_ski Staff Join Date: Apr 2006 Location: Illinois, USA Posts: 8,841 (3.40/day) Thanks: 3,001 Thanked 3,306 Times in 2,528 Posts System Specs	Glad to see you're still going with this, but I'd love to see it come along a little faster __________________ t_ski's stuff for sale ~ TPU Eyefinity Club ~ Heatware Silverstone TJ07 build ~ Mini ITX Home Server build Intel i7 3930K ~ Asus P9X79 Pro ~ 4 x 8GB Corsair Dominator Platinum 1866 C9 ~ Triple 7970's with EK FC-7970 CSQ ~ Triple Asus VW246H LCD's ~ 2 x 120 GB Corsair Force 3 (Raid 0) ~ 500GB WD ~ Lite-On BluRay ~ Nickel-plated Heatkiller 3.0 CU ~ D5 with EK X-top ~ BIX Quad Rad ~ Corsair AX1200 ~ Silverstone TJ07

System Name:	My i7 Beast
Processor:	Intel Core i7 3930K
Motherboard:	Asus P9X79 Pro
Cooling:	Heatkiller 3.0 Nickel, three FC-7970 CSQ with an FC-link , D5 with EK X-top Rev2 & BIX Quad Radiator
Memory:	4 x 8GB Corsair Dominator GT DDR3-1866
Video Card:	Two Sapphire 7970's + Asus 7970
Hard Disk:	2 x 120GB Corsair Force 3 SSDs in Raid 0 + 500GB WD
Optical Drive:	Lite-On BR Reader
CRT/LCD Model:	Three Asus 24" VW246H LCD's
Case:	Silverstone TJ07
Sound Card:	Onboard
PSU:	Corsair AX1200
Software:	Windows 7 x64 Ultimate

System Name:	hmmm...
Processor:	i7 3770K
Motherboard:	Asus Maximus V Gene
Cooling:	CM Hyper 212 EVO w/ AP-29s in push/pull
Memory:	4x4gb DDR3 1600mhz G-Skill Ripjaws-X
Video Card:	PowerColor HD7970
Hard Disk:	OCZ Vertex 4 256gb + 2x1tb WD10EARS + 1x2tb WD10EARS
Optical Drive:	None
CRT/LCD Model:	Samsung Syncmaster 226BW
Case:	Fractal Design Define Mini w/ 3 AP-30s intake and 1 AP-30 outtake
Sound Card:	Onboard+Logitech Z623
PSU:	Corsair AX650
Software:	Windows 7 Professional x64

May 7, 2012, 03:33 AM	#79
johnnyfiive Join Date: Apr 2008 Location: Tucson, AZ Posts: 2,975 (1.60/day) Thanks: 740 Thanked 856 Times in 537 Posts System Specs	Whoa, awesome progress! This thing is going to look awesome! __________________ [o_0] - GO BUCKEYES! ------------------------------------------------------ HEATWARE /MY KEYBOARD / VIDEO OF MY LGA 2011 RIG ------------------------------------------------------ Steam: johnnyfiive ORIGIN: johnny5iive League of Legends: 5iive

System Name:	K6-II 8320
Processor:	FX 8320 @ 4.7GHz (1.476v)
Motherboard:	Gigabyte 970 UD3
Cooling:	Corsair H100
Memory:	GSkill Ares 1866 8GB
Video Card:	Gigabyte 7870
Hard Disk:	Intel 330 120GB
Optical Drive:	LG R/W+/-[0_o]/
CRT/LCD Model:	Dell UltraSharp U2713HM
Case:	Corsair 400R
Sound Card:	Onboard
PSU:	Corsair GS700
Software:	Windows 8 Professional 64-Bit

Apr 17, 2012, 03:05 AM	#77
adulaamin Join Date: Aug 2009 Location: Philippines Posts: 397 (0.29/day) Thanks: 1,004 Thanked 99 Times in 67 Posts System Specs	Man I wish I had the resources and skills to do what you do... AWESOME job so far... Can't wait to see it finished...

May 7, 2012, 03:14 AM	#78
Spotswood Join Date: Sep 2009 Location: New Hampshire, USA Posts: 118 (0.09/day) Thanks: 46 Thanked 170 Times in 73 Posts	I made a mistake, placing the false back too far into the case, which required having to re-fabricate the back sheet. But I figured I could take advantage of the situation by improving the mounting of the motherboard tray, by fastening the tray to the false back with a 7/8-inch long spacer. I don't remember if I already offered this tip before, but I try to reduce the wear and tear on my 1/2-inch flush cutting router bit by first rough cutting with a 3/16-inch spiral downward cutting bit.

May 28, 2012, 03:34 AM	#80
Spotswood Join Date: Sep 2009 Location: New Hampshire, USA Posts: 118 (0.09/day) Thanks: 46 Thanked 170 Times in 73 Posts	A PSU mounting plate was routed out of a piece .10-inch thick aluminum sheet with the help of a custom template. In order to accurately transfer the locations of the PSU mounting holes, threaded hole transfer punches (mcmaster.com part # 3385A31) were threaded into a PSU. And then the PSU was carefully centered and pressed into the sheeting, with the end result being a perfect squarely mounted PSU.

May 28, 2012, 03:36 AM	#81
Phusius Banned Join Date: Mar 2012 Posts: 1,262 (2.96/day) Thanks: 621 Thanked 380 Times in 208 Posts System Specs	faster! faster! ::cracks whip:: thats what she said

Processor:	i5-2500k @ 4.5
Motherboard:	Asus Z68 Deluxe
Cooling:	Noctua NH-D14
Memory:	16GB DDR3 1600
Video Card:	Sapphire 7950 @ 1200/1475 @ 1175v
CRT/LCD Model:	Dell 23" 2ms
Case:	Carbide 500r
Sound Card:	Asus Xonar DG

System Name:	SuperDuperUberComputer
Processor:	AMD Phenom II 945 X4 3.0Ghz
Motherboard:	ASRock 990FX Extreme 4
Cooling:	CM Hyper 212 EVO push:pull+ 1 panaflow 113CFM + 2 x 120mm NZXTs
Memory:	2x4GB DDR3 Corsair Vengeance 1600MHz CL9
Video Card:	GIGABYTE GTS450 OC2
Hard Disk:	SATA II 80GB Hitachi 7200RPM,W.D 500GB Green \|\| 4GB int + random SD cards
Optical Drive:	ASUS DVD drive
CRT/LCD Model:	Samsung Sync Master 793s CRT\|
Case:	NZXT Guardian 921RB
Sound Card:	Realtek ALC892 with THX True Studio
PSU:	Corsair GS600
Software:	Windows 7 64bit
Benchmarks:	real men dont need to bench :p

Jun 4, 2012, 03:08 AM	#84
Spotswood Join Date: Sep 2009 Location: New Hampshire, USA Posts: 118 (0.09/day) Thanks: 46 Thanked 170 Times in 73 Posts	Another router template was made to cutout the areas for the PSUs out of the back sheet. A guide was clamped to the bottom of the template to keep the cutouts perfectly aligned along the bottom.

Aug 19, 2012, 12:43 AM	#85
Spotswood Join Date: Sep 2009 Location: New Hampshire, USA Posts: 118 (0.09/day) Thanks: 46 Thanked 170 Times in 73 Posts	Turned out that I needed to cut one more slot out of the bottom shelf. But the last time I used my wooden "small slot" router template, I somehow managed to crush one edge, so I quickly cobbled together a new out of some left over t-slot extrusion. I'm really loving using these t-slot extrusions to make router templates - fast and accurate! Here's a teeth-shattering video of me cutting out the slot. __________________ Rich Custom Case Builder Latest project: Project: Server and Gaming Case Project: Aluminum Water Cooling Case

Sep 10, 2012, 01:15 AM	#86
Spotswood Join Date: Sep 2009 Location: New Hampshire, USA Posts: 118 (0.09/day) Thanks: 46 Thanked 170 Times in 73 Posts	Performed the mind-numbing task of fastening the bottom and top sheets to the case frame via flat head socket cap screws. Through and countersink holes were drilled into the sheet and transferred to the case frame via a self-centering counterbore drill bit. Bottom sheet all fastened: And top sheet all drilled out:

Sep 10, 2012, 01:44 AM	#87
mediasorcerer Join Date: Sep 2011 Location: coast ,melbourne Posts: 942 (1.53/day) Thanks: 709 Thanked 235 Times in 169 Posts System Specs	What a monster, pleasing to see your metalwork, inspiring and thanx! How will you finish the aluminium? what about anodizing in a color?? __________________ his masters voice Illuminous Epanoia Technocrati

System Name:	THE MEDIAMACHINE
Processor:	i5-3570k
Motherboard:	Asus gene v z-77 matx.
Cooling:	Antec h20 620
Memory:	2x4gb g.skill ripjaws z 2400
Video Card:	h.i.s radeon 7950 reference 3 gb- hooray!!!
Hard Disk:	samsung 128gb~830 ssd. samsung 500gb hdrive.
Optical Drive:	samsung super writemaster
CRT/LCD Model:	22 inch tele.
Case:	circa 1996 grey rat box with no sides front.until my own is finished
Sound Card:	inbuilt creative.supreme effects 3
PSU:	thermaltake tt-500w
Software:	win 7 x64-
Benchmarks:	Coming soon

Sep 10, 2012, 01:57 AM	#89
mediasorcerer Join Date: Sep 2011 Location: coast ,melbourne Posts: 942 (1.53/day) Thanks: 709 Thanked 235 Times in 169 Posts System Specs	I used to do casting in aluminium, it can look great polished, but does oxidise slightly over time, black powdercoat sounds beautiful. cant wait to see it! __________________ his masters voice Illuminous Epanoia Technocrati

Nov 5, 2012, 03:58 AM	#90
Spotswood Join Date: Sep 2009 Location: New Hampshire, USA Posts: 118 (0.09/day) Thanks: 46 Thanked 170 Times in 73 Posts	Drilled out the holes for the vandal resistant switches and fastened the front sheeting to the case.

Nov 5, 2012, 04:01 AM	#91
HammerON The Watchful Moderator Join Date: Mar 2009 Location: The Cold North Posts: 4,352 (2.82/day) Thanks: 3,983 Thanked 2,878 Times in 1,542 Posts System Specs	Long time no see Glad to see you are making progress

System Name:	Cruncher/Gamer
Processor:	i7 970
Motherboard:	ASUS Rampage III Extreme
Cooling:	H2O
Memory:	Patriot Viper Extreme 12GB 2000
Video Card:	2x VisionTek HD 7970's
Hard Disk:	OCZ Vertex 4 256GB x2 in Raid0 + WD 640GB
Optical Drive:	ASUS Blu-Ray
CRT/LCD Model:	Dell UltraSharp U3011 30"
Case:	Corsair Obsidian 800D
Sound Card:	On-board
PSU:	Corsair AX1200
Software:	Win 7 64bit
Benchmarks:	Always changing~

Nov 6, 2012, 12:36 PM	#92
de.das.dude Join Date: Jun 2010 Location: Wild Wild East Posts: 4,574 (4.25/day) Thanks: 2,335 Thanked 1,338 Times in 916 Posts System Specs	i thought you had forgotten us XD __________________ my wallet isnt hashwell compatiple sad face

Nov 21, 2012, 03:09 AM	#93
Spotswood Join Date: Sep 2009 Location: New Hampshire, USA Posts: 118 (0.09/day) Thanks: 46 Thanked 170 Times in 73 Posts	Finished the lower portion of the back sheet, which involved installing the PEM nuts, trimming the PSU mounting plates to the final size and creating an extra solid cover plate (which I almost forgot to do).

Nov 21, 2012, 04:20 AM	#94
adulaamin Join Date: Aug 2009 Location: Philippines Posts: 397 (0.29/day) Thanks: 1,004 Thanked 99 Times in 67 Posts System Specs	I am in AWE... Keep it coming... Keep it coming...

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