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Project: Aluminum Water Cooling Case

Discussion in 'Project Logs' started by Spotswood, Apr 17, 2011.

  1. Spotswood

    Spotswood

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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

    [​IMG]

    [​IMG]

    [​IMG]

    Stay tuned!
     
    adulaamin and Cold Storm say thanks.
  2. t_ski

    t_ski Former Staff

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    In the for the first sub :toast:
     
    Chicken Patty and Spotswood say thanks.
    Crunching for Team TPU
  3. Spotswood

    Spotswood

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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:

    [​IMG]


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

    [​IMG]



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

    [​IMG]


    [​IMG]
     
    Cold Storm says thanks.
  4. Funtoss

    Funtoss New Member

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    How much did all these cost you!?
    it looks so nice!
     
  5. Eric_On_Web New Member

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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
     
  6. Spotswood

    Spotswood

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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.

    [​IMG]


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

    [​IMG]

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

    [​IMG]


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

    [​IMG]


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

    [​IMG]
     
    Cold Storm says thanks.
  7. lonewolf

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    that is just awsome. I want one!
     
    Spotswood says thanks.
  8. Cold Storm

    Cold Storm Battosai

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

    :toast:
     
    Spotswood says thanks.
  9. gumpty

    gumpty

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    Subbed.

    That is one huge case.

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

    Huge.
     
  10. DrunkenMafia

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    That thing will be solid!! Love it :)
     
  11. mATrIxLord New Member

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    subed.... i wanna see how this goes... it will give me a few ideas...
     
  12. Spotswood

    Spotswood

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    The 5.25-inch drive bay rails finally came back from a local fabricator.

    [​IMG]


    And a 140x4 rad arrived in the shop.

    [​IMG]

    [​IMG]
     
    Cold Storm says thanks.
  13. Wile E

    Wile E Power User

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    Hmmm, subbed.
     
  14. >>PhoeniX<<

    >>PhoeniX<< New Member

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    Subbed :) Looks great
     
    Spotswood says thanks.
  15. Blue-Tiger

    Blue-Tiger New Member

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    Subbed, the model looks soo clean! :D
     
    Spotswood says thanks.
  16. Spotswood

    Spotswood

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    Next up is to cut the front sheet.

    [​IMG]


    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.

    [​IMG]


    The aluminum bits guided my flush trimming router bit.

    [​IMG]


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

    [​IMG]

    [​IMG]


    Now I just need to square all of the corners and cut to width. Ugh.
     
    PopcornMachine says thanks.
  17. PopcornMachine

    PopcornMachine

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    Another huge case. That is one big radiator you've got there.
     
    Spotswood says thanks.
  18. ERazer

    ERazer

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    subd! this guys projects r EPIC!!! :respect::respect:
     
    Spotswood says thanks.
  19. Chicken Patty

    Chicken Patty WCG Moderator Staff Member

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    Subbed, this looks good. :)
     
    Spotswood says thanks.
  20. DrunkenMafia

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    more?? pleease!! Loving the fabrication on this project. :)
     
  21. Spotswood

    Spotswood

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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.

    [​IMG]
     
  22. HammerON

    HammerON The Watchful Moderator Staff Member

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    Sub'd. Glad to see you building another monster case!
     
    Spotswood says thanks.
    Crunching for Team TPU
  23. fullinfusion

    fullinfusion 1.21 Gigawatts

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    Subbed, this is going to be good :rockout:
     
  24. Wile E

    Wile E Power User

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  25. Spotswood

    Spotswood

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    Yep.
     

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