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Project: Aluminum Water Cooling Case

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

  1. t_ski

    t_ski Former Staff

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    Glad to see you're still going with this, but I'd love to see it come along a little faster :p
     
    Crunching for Team TPU
  2. adulaamin

    adulaamin

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    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... :toast:
     
    Crunching for Team TPU
  3. Spotswood

    Spotswood

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    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.

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    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.

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  4. johnnyfiive

    johnnyfiive

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    Whoa, awesome progress! This thing is going to look awesome!
     
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  5. Spotswood

    Spotswood

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    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.

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

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  6. Phusius

    Phusius New Member

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    faster! faster! ::cracks whip::

    thats what she said
     
  7. de.das.dude

    de.das.dude Pro Indian Modder

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    thats a nifty piece of tool right there :O
     
  8. t_ski

    t_ski Former Staff

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    Agreed. Spotswood, your builds are awesome, but they take just too damn long :laugh:
     
    Crunching for Team TPU
  9. Spotswood

    Spotswood

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    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.

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  10. Spotswood

    Spotswood

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    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!

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



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  11. Spotswood

    Spotswood

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    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.

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    Bottom sheet all fastened:

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    And top sheet all drilled out:

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  12. mediasorcerer New Member

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

    Spotswood

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    Thanks. Current thinking is for a black powdercoat finish.
     
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  14. mediasorcerer New Member

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    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!
     
  15. Spotswood

    Spotswood

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

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  16. HammerON

    HammerON The Watchful Moderator Staff Member

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    Long time no see:)
    Glad to see you are making progress:toast:
     
    Crunching for Team TPU
  17. de.das.dude

    de.das.dude Pro Indian Modder

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    i thought you had forgotten us XD
     
  18. Spotswood

    Spotswood

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    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).

    [​IMG]
     
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  19. adulaamin

    adulaamin

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    I am in AWE... :toast:

    Keep it coming... Keep it coming... :D
     
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    Crunching for Team TPU

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