The Mini-ITX build begins.

[pantherx12]

Aye I mentioned the same thing earlier.

Have you thought about getting some full copper heat sinks by the by?

I've seen ones that would suit your needs for around 10 pounds, if you can find them second hand even cheaper eh

[Cuzza]

all this heatsink building has inspired me. I'm going to get on Sketchup and design me a custom heatsink for my Sega

[Lazzer408]

The piece in the middle is making contact. It's the aluminums thermal conduction rate that's any limiting factor. I didn't expect the whole assembly to be the same temperature. For now it's working good enough. Nothing gets to hot to touch except the graphics card. I'm sure that will fail in a few months due to thermal induced bga seperation but hey, thats planned obsolescence for ya.

[Lazzer408]

After a few days of testing and fiddling I've come to one conclusion. It's too #ukin' small!

The top cover is only 1/4" from the top of the Intel cooler. This seriously effects the performance it. The NB is cooled by the airflow from the cpu fan and it's being effected even worse. I can't keep my finger on the NB heatsink after about 10min of prime95 with the top cover on. The PSU is acceptable. It's 'very warm' but not hot. I can keep my finger on it without feeling pain.

I keep telling myself "If this was moved there and that over here and these over there everything would work out". I should have build my own case having ALL the parts on hand. That way I'd know they would all fit.

One option is to cut the bottom out of the case and drop it down 1/2". There's a few advantages to going that route. It allows 3x more space above the cpu cooler, give more room under the videocard to fit a full thickness 3-1/2" hdd, and gives 1/2 more room for the power supply which would allow me to cut fins directly in the top of the aluminum plate 'heatpipe' I'm using for getting the heat to the psu heatsink. It would also allow me to use a 450w 1U server power supply. A PCIe extention will work out for the riser to make it back to the motherboard. Using a laptop harddrive, a double slot graphics card would fit. A 5870? 1/2" gets me a 5870? That's already looking like a win.

Second option is to just make a new case about the same size as this one. I'd actually be using the front panel off this case, but, the power/reset buttons/LEDs and usb board are still in the way unless I make the case about 1/2" deeper. I guess I can make it w/e I need if I'm making it. lol

Any input? Mod this case or make a new one?

[Cuzza]

Surely 5870 is far too long?!

Don't give up on what you've done so far man. I reckon you can figure this thing out without any drastic changes. Have you looked for a lower profile HSF for the processor? You could also cut back to a lower GHz chip if you can get hold of one, one of those low TDP pentiums (last resort!)

Also , more fans in the side of the case next to the CPU? Put a fan on the chipset.? just throwin ideas about.

Cuzza

[Lazzer408]

Originally Posted by Cuzza

Surely 5870 is far too long?!

Don't give up on what you've done so far man. I reckon you can figure this thing out without any drastic changes. Have you looked for a lower profile HSF for the processor? You could also cut back to a lower GHz chip if you can get hold of one, one of those low TDP pentiums (last resort!)

Also , more fans in the side of the case next to the CPU? Put a fan on the chipset.? just throwin ideas about.

Cuzza

All good ideas. Holes in the top cover would easily take care of the cpu cooling needs but I'd rather not have any openings in the top to keep dust and debris from falling in. The goal is to get the fastest ITX system in the smallest space. The case will only be what is absolutely necessary to physically fit the components, including the power supply, a beefy graphics card, and maintain adequate cooling. The gpu should exhaust it's own heat. When I'm done the case will only be about 1/2 taller and 1/2" deeper and with that I can fit a 2 slot videocard, laptop hdd, and a 450w server psu. The buttons/LEDs/USB will be relocated to the left hand side. I'll post a pic of the modified front view in a moment.

There seems to be a standard in powersupply pcb's for flex atx and 1U servers. They are 3.75" wide. The space between the motherboard and the case front is about 3.625". Then comes the issue of the buttons/LEDs/USBs in the way for mounting there. That is why the PSU is being crammed under the videocard currently. If I have to use a bare psu I'd rather put the heatsink under the videocard, because it's smaller, and the psu pcb under the optical bay.

I'm drawing up something in paint now trying to take measurments and such for a CAD drawing later. The new case design will allow for 3x 60mm fans on the right side and one 60mm in the bottom for the psu if need be. The CPU will get it's own air from the rear of the case. I'll put up a pic of that plan also.

I'm happy with how things have worked out so far. I honestly thought the 300w psu would have popped during load testing but as hot as it was it survived. I'm afraid it's the long term abuse that will blow it out 6mo from now.

[Geofrancis]

if its all working alright now with the case on then leave it till it pops.

have you tried hooking a watt meter to see what your pulling from the psu?

those single slot 4850's run HOT damn hot and the fan goes like fuck i seen mine at over 8000rpm! its like a jet engine i can barely hear the tv because of it. thats why im running my computer without the case just now.

[Lazzer408]

This would be the new front panel. I'd reuse the billet aluminum existing front panel but 1/2" below it would be flat steel. This is where the buttons/leds/usb goes. The reason for relocating them is to make room under the optical bay for a 450w 1U supply. With the height of the case increased 1/2" it won't be a problem to fit this in the case. I'm probably not using this -exact- 1U supply. The other one I ordered is 320w and about 2" shorter then this one. That will allow a 2 slot graphics card to clear it on that end.

[Lazzer408]

Another option other then the 1U supply would be a flex-atx like this one.

http://cgi.ebay.com/Sparkle-Power-SP...item587e71c71a

It is 5.9" long and would fit about so... Or like in the second pic. It's own fan would vent outside the case on the right side. Same side as the other 3 60mm fans I'll be adding. Note the CPU fan. The blue arrows above it are an intake vent at the back of the case. I'll show you then in a moment.

[stevednmc]

Ive been following this thread for a while now and must say this is some sweet engineering!

[Lazzer408]

To explain a bit better about the cpu intake...

Currently there is only 1/4" between the top of the Intel cooler and the case cover. The new case essentially has the bottom dropped 1/2" so this will make 3/4" of space. Plenty of room for an air duct. Here's a basic idea of how the duct will channel air to the cpu. The lines and cooler you see are hidden lines under the cover but show how the duct gets cool air to the cpu. Think of it shapped like a gpu cooler's plastic cover but the air is flowing the other direction.

[_Zod_]

Why not just vent the cover above the CPU?

[Lazzer408]

Originally Posted by _Zod_

Why not just vent the cover above the CPU?

Originally Posted by Lazzer408

I'd rather not have any openings in the top to keep dust and debris from falling in.

I did mention it.

[Lazzer408]

Here's how the back view would look.

[Cuzza]

cpu airduct is great idea

[Lazzer408]

Here we go like this. This will be made out of steel then tacked on the top case cover. This forces the cpu cooler to get all of it's air from the rear of the case. It looks kinda big and probably is. In reality it will sit with the cpu fan slightly inside of the duct.

[Lazzer408]

Huston it's a go!

This morning I picked up a 12x11" 1/4" thick aluminum plate that will become the bottom of the new case. The top cover will be U shaped and slip over the sides of the computer and screw into holes in the side edges of the bottom plate. The cover will be aluminum as well and painted semi-flat black. The width is going to be a bit more then the faceplate from this g-atlanta case but I'll be making a new faceplate to cover the whole front rather then leave the 1/2" gap at the bottom. This allows me to use the old power button/LED assembly as well. Once everything is done and in place I'll remove the bottom plate and have small fins milled on each side.

The new specs:

-Standard Flex ATX power supply 320w
-Intel E6750 2.66@3.2ghz
-Standard height Intel stock cooler (rather then the shorty)
-HD5870 graphics card (double slot card) (HD4850 for now)
-3.5" standard hdd or 2x laptop hdds (hdds bolted to bottom plate for cooling)
-DVD-RW DL 8x slim optical drive
-2x front USB
-WiFi, LAN, HD audio, ect.

It will have a fresh air ducted rear CPU intake and 3x60mm thermally PWM controlled case fans blowing out opposite the gpu side. The gpu get's the cold air first and vents it's own hot air. There will be room for an additional 60mm fan in the bottom of the case that will be located directly below the regulator area of the videocard. Close enough that the gpu fan should get a nice blast of fresh air from that fan. The PSU has it's own internal quiet fan and vents it's own hot air. The CPU is the only heat generating component that does not vent it's own hot air but it located 1/2" from 2 of the 60mm fans.

I should have some pics up later today. I'm heading to the shop now to mill my baseplate to spec and bend my new top cover.

[_Zod_]

Originally Posted by Lazzer408

I did mention it.

You could filter it, it's not really a big deal unless you planned on stacking crap on top of the unit which would be unwise anyway. But I see you rather enjoy doing things the hard way

[[Ion]]

Awesome, this looks sweet, I can't wait to see how this turns out. I want something smaller than the SG05, it's too big IMO

[pantherx12]

I do love this build, but I'm so impatient, I just love seeing the new pictures!

Looking forward to the next set.

[Lazzer408]

Have to start somewhere.

[Lazzer408]

The pattern is transfered then the plate is drilled and tapped. It uses standard brass stand-offs but for now these plastic clip in ones will come in handy.

[KieranD]

so your fixing the case to fit the cooler right? i dont quite understand man

[Lazzer408]

Originally Posted by KieranD

so your fixing the case to fit the cooler right? i dont quite understand man

Sorry, I've been all over the place with this project.

I'm building a new case from scratch. It's -about- 5/8" taller, 1/8" wider, and 1-1/4" deeper then the black G-Atlanta case you see in most of the pics. The height change was to allow for double slot graphics cards, full size 3-1/2" hdd, better cpu cooling, and a Flex-ATX/1U power supply. The depth change was also to make room for Flex-ATX/1U power supplies ranging from 200w to 450w. The width change of 1/8" was to allow side fans on the left side if needed and put the total width at 12".

The aluminum plate in the last pic is the bottom of the case. Essentially what I'm doing is building this from the inside out to be as small as possible.

[KieranD]

Originally Posted by Lazzer408

Sorry, I've been all over the place with this project.

I'm building a new case from scratch. It's -about- 5/8" taller, 1/8" wider, and 1-1/4" deeper then the black G-Atlanta case you see in most of the pics. The height change was to allow for double slot graphics cards, full size 3-1/2" hdd, better cpu cooling, and a Flex-ATX/1U power supply. The depth change was also to make room for Flex-ATX/1U power supplies ranging from 200w to 450w. The width change of 1/8" was to allow side fans on the left side if needed and put the total width at 12".

The aluminum plate in the last pic is the bottom of the case. Essentially what I'm doing is building this from the inside out to be as small as possible.

okay i understand sounds good to me, im keeping an eye out

i was interested at the start then i lost it a bit rofl but thanks for clearing it up for me