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Project: Honeycomb

Discussion in 'Project Logs' started by Fuganater, Jul 7, 2011.

  1. Fuganater New Member

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    [​IMG]

    Honeycomb will by a scratch build, double wide server case.

    This mod is brought to you by:
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    Thanks to John and his team at Delvie's for helping with the Plexi!

    [​IMG]
    Thanks to Bill for providing some goodies!

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    Thanks to Maurizio at Lamptron for providing a fan controller and some UV Cold Cathodes.

    [​IMG]
    Thanks go Gregor at EK for providing a bunch of the watercooling parts.

    Hardware
    Motherboard: Gigabyte 880GA
    CPU: AMD Athlon II X4 640 @3.0GHz
    GPU: 2x something
    HDD: 1x 320 HDD (OS), 2x 2TB HDDs (Case can hold roughly HDDs 20 total)
    PSU: Corsair 100W
    Optical Drive: Blu-ray Player
    RAM: 4GB G.Skill PC 1600


    The Case

    Here are my original Sketchup designs.
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    Updates:
    Update #1: Received Mobo and Plexi Sizes
    Update #2: Received more parts
    Update #3: The Saw
    Update #4: Drill Press
    UPdate #5: New Mobo Side Panel Design
    Update #6: Testing
    Update #7: Case Fans
    Update #8: An Evening Designing
    Update #9: MNPCTECH Sponsor
    Update #10: Experimenting
    Update #11: Fabricating
    Update #12: Finishing the Frame
    Update #13: Plexi Work
    Update #14: Lamptron Sponsor
    Update #15: MNPCTECH Goodies
    Update #16: How I Keep it Together
    Update #17: EK Waterblocks Sponsor
    Update #18: Woe Is Me
    Update #19: Front Panel
    Update #20: Lamptron Goodies
    Update #21: Media Card Reader Cutout
    Update #22: Coming Together and Side Panel Design
    Update #23: Cutting the Mobo Side Panel
    Update #24: Custom Waterblock and Cables
    Update #25: EK Waterblocks Goodies
    Update #26: Installing the Rad/Res
    Update #27: Lighting
    Update #28: Supplies, Rivets and Sleeving
    Last edited: Feb 4, 2012
  2. Fuganater New Member

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    Got my mobo in today!

    [​IMG]

    Here is the final cut of plexi sizes.

    1 sheet of:
    • 17 1/2" x 17 1/2" Black Plexiglass 1/4" Thickness - BACK
    • 17 1/2" x 17 1/2" Clear Acrylic Plexiglass 1/4" Thickness - FRONT
    • 18" x 18" Black Plexiglass 1/4" Thickness - BOTTOM
    • 18" x 17 1/2" Black Plexiglass 1/4" Thickness - TOP
    • 16" x 17 1/2" Black Plexiglass 1/2" Thickness - CENTER
    • 12 1/4" x 4 1/4" Black Plexiglass 1/4" Thickness - PSU COVER

    2 Sheets of:
    • 17 3/4" x 18" Clear Acrylic Plexiglass 1/4" Thickness - SIDES


    4 Sheets of:
    • 4" x 17 1/2" Black Plexiglass 1/4" Thickness - HDD RACKS


    12 - 1" x 1" Clear Acrylic Plexiglass cubes- CORNER SUPPORTS

    4 -1" Transparent Amber Extruded Transparent Colored Acrylic Plexiglass Rod 1" diameter - CASE FEET


    Cheers till later.
  3. Fuganater New Member

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    Finally got parts in.

    AMD Athlon II X4 640
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    XSPC 2 meter Orange LED kit
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    OCZ 1000W PSU
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    Came with these nifty Velcro ties.
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    2x2GB G.Skill RAM PC 1600
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    Media Card reader
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    Lots of Orange sleeving and shrink tubing.
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    Still waiting for the framing and for my sponsor to reply about the Plexi.

    Cheers till later.
  4. Fuganater New Member

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    Got my saw yesterday :D Just waiting on a few more things to arrive then its off to work!

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    All put together!
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    New blad installed.
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    I should be finalizing the deal with my sponsor on the plexi today or tomorrow then hes shipping it all to me. Hopefully I get the drill press soon.

    Cheers till later.
  5. Fuganater New Member

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    Got my Drill Press today :D

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    Not as many pieces as I was expecting.

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    All done.
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    Vise
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    Circle cutter for the fan holes.
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    Cheers till next time.
    Last edited: Jul 7, 2011
  6. Fuganater New Member

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    Started working on the side panel again. I wasn't happy with the last one so here is the new one so far.

    [​IMG]

    Going to be doing more work tonight on it.
  7. Fuganater New Member

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    Got the motherboard tray from Mountain Mods finally and I decided its time to test out the hardware to make sure its all good. I didn't attach the other back part that had the fan hole in it because it will just get in the way when I go to mount this to the case.

    [​IMG]

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    Mobo, RAM and Power/Reset switches installed.
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    CPU
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    PSU
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    Since Everything was hooked up correctly I figured it was time to power it up. I flicked the switch on the PSU and hit the Power button and BOOM. The freaking $200 PSU blew up. I was so mad. Luckily I have my old one that I'm giving my sister.

    [​IMG]

    That PSU booted just fine. I started the RMA already with Newegg for the PSU so I need to mail that out tomorrow.

    Here are the switches in the dark. The "O" one is power and the dot one is the reset button. I put the LED for the reset to the HDD activity LED so it gets lit and I can see the HDD activity! 2 with 1 is good!
    [​IMG]

    Everything after that went pretty smooth. I found out that my SATA DVD drive was bad so I put on an old IDE one and it installed WHS just fine.

    My Plexi sponsor is sending me the plexi tomorrow or Friday so I should have it in about a week and then I can remeasure everything and start cutting the frame. Once that is built I will start to figure out how to mount all the plexi to it.

    Cheers till then.
  8. Fuganater New Member

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    Got my order in from Newegg with some nice case fans!
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    8x Zigmatek 140mm Orange fans with White LEDs
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    They have small blades but they move a ton of air.
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    Now lets make them look pretty!

    Removed the sticker.
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    Sleeve them!!
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    At first I kept the stock white connector but I then decided that it would look funny and stand out. So I replaced them with the black ones I ordered for the fan extension cables. Didn't take a pick but they look good.
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    All of them done.
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    I got bored last night so I figured I would start cutting the shrink tubing to 15mm lengths.

    14.99.... close enough
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    These are all ready
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    Need to trim these ones down later. They are about 1mm off. Maybe less. Just need to trim a hair off of them.
    [​IMG]

    Cheers till next time.
    CrackerJack and de.das.dude say thanks.
  9. Fuganater New Member

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    double post...
    Last edited: Jul 7, 2011
  10. ERazer

    ERazer New Member

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    sub'd

    looking good :D
  11. Fuganater New Member

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    So I spent the past 6 hours roughly working on the design. Leaning some new techniques too.

    Here are the shots I took after figuring out how to get Kerkythea and Sketchup v8 to play nice. They are all very low res for now. The final design will be all high res. They will take probably close to 15-30 minutes to render ^^

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    Inside the mobo side
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    You can see I started playing with the cabling up top where the ATX Power cable comes through the pelxi.

    HDD side
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    Now in the middle I had an ingenious to hide my cabling. I would put a piece of plexi down the center about 1 to 1.5" off the center panel. It would be anchored with nuts and bolts and I'll use aluminum spacers to make it sturdy and exact. there is also a piece of orange pexi that will either be UV reactive or have LEDs in it.

    This is not the final layout. Its getting close but isn't there yet. Lets see if I can score a WC sponsor or 2 and then we will have some major changes. I have them in mind but don't want to jinx myself by making the model yet.

    I found a few things out and I just might have to put some tutorials together for everyone. But that will take a few days.

    Cheers till next time.
    PopcornMachine says thanks.
  12. Fuganater New Member

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    Thanks man!! Big update coming this weekend. Just catching this forum up on my progress.
  13. mATrIxLord New Member

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    subed.... looking really good dude... waiting on moar pics :D
    Fuganater says thanks.
  14. Fuganater New Member

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    I'm glad you like it! Just scored another sponsor and a PR firm for reviews.
  15. t_ski

    t_ski Former Staff

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    Reminds me of the mini ITX build on [H]
    Crunching for Team TPU
  16. PopcornMachine

    PopcornMachine

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    Have an idea in my head for something similar. Looking forward to how it turns out.
  17. Fuganater New Member

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    I got my 2nd sponsor!
    [​IMG]
    Big thanks to Bill at MNPCTECH! He will be providing some Billet Machined Aluminum case feet, 2 types of modders mesh and a Beer Bottle Opener!
  18. Sir B. Fannybottom

    Sir B. Fannybottom

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    That thing is sexxxxy! Congrats on the sponsors!
  19. Izliecies New Member

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    is that like some kind of server?
  20. Fuganater New Member

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    Line one of the first post...
  21. Fuganater New Member

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    Since this is my first scratch build I am a bit out of my comfort zone. Before I get to what I did here is some stuff I received.

    Orange LED strip
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    Its not very bright for being 12v....
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    Honeycomb mesh from MNPCTECH
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    It had a thick end to it that had to go.
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    Tin snips worked great but this is what I had left.
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    So on to some real modding...

    I had some scrap pelxi left over from an old mod that I started expermenting on. I traced a 140mm hole on it and started drilling.
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    And after the first round of sanding.
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    2nd round
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    3rd round was finally enough. Here it is with a fan.
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    Its not 100% smooth but its damn close. I'll probably use a 140mm hole saw on the actual case plexi. This was me trying it out by hand.

    Now to the frame. Here is the little mock up I made so I could figure out the best joint to use.
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    It proved to be pretty sturdy. It's not exact... so I have to make sure my cuts on the real pieces are exactly on.
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    So to solve the gap I used some J-B Weld.
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    Its curing right now. I'll sand it later tonight or tomorrow and post pics of how it looks.

    Here are the screws I will be using. 6/32 self tapping hex head screws.
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    They grip like nothing else. Greatly improves the joint over the crappy screws I used at first. I might switch these for some black anodized hex head screws that I'm using everywhere else in the case.

    And finally I didn't want the mesh to look all flat and lame. I wanted it to be "domed". So I cut a peice, put it in the mock 140mm hole and pouned it with a rubber mallet. It came out rather well.
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    Well that's it for today. I have a 3 day weekend so expect another update. Hopefully I can get the frame done this weekend.

    Cheers till next time.
    PopcornMachine says thanks.
  22. Fuganater New Member

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    Fabricating

    I worked all day today fabricating the frame. Too a lot longer than I was expecting but I guess that's the price to get it right the first time. Well... pretty right. There are some small gaps but I knew that would happen because the L brackets I made are not exactly at 90 degrees.

    Here are the brackets. I cut 1"x1" 1/8" thick angled aluminum in 1/2" sections.
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    I then measured and drilled the holes for the screws. Very easy but time consuming job when I needed 32 of them. Plus spares.

    The first side cut.
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    And all put together.
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    I then measured the straight peices that connect both sides together and cut, drilled and installed them on one of the side pieces. (Sorry about the yellowish images. I took these at night so no natural light coming in the window.)
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    No real gaps like my small model I made so that's a good start. I won't have to use too much J-B Weld to fill the gaps.

    I then put the other side on top so I could make sure it came to 18" exacly from end to end and it didn't... I was 1/8" off on all legs. So I marked them and will be cutting them down first thing in the morning. Its too late to cut now.
    [​IMG]

    More work on the frame tomorrow and probably starting to map out the cuts in the acrylic. I probably won't cut any of it until after my vacation.

    Cheers till next time.
  23. Fuganater New Member

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    Finishing the Frame

    I finished putting the frame together and I have to say, its really nice to finally see something from this mod.

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    Now that it is all together lets see how the plexi aligns with it. Hmm... a bit off...
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    Ok so 3 corners are too high. Well that's better than being too low. Can't add but I can cut. So after about another 4 hours of cutting, re-drilling and recreating 3 of the parts everything aligned nicely.

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    Just perfect!
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    Man... this piece is about 2mm off... Its the side so its not a huge deal so I'm going to let it ride for now. If it looks horrible later than I can remake the 2 pieces. They are very easy because they are not angled. Just straight pieces.

    Now here is a 2mm gap.
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    I took the dremel to that back corner and shaved away some of the aluminum. We will see how it aligns again later.

    Since everything was good except for those 2 parts I decided to start the J-B Weld process.
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    It has to cure for 6 hours before I can work on it again so maybe tonight before bed I can sand it down.

    Cheers till next time.
  24. de.das.dude

    de.das.dude Pro Indian Modder

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    nice work.


    im guessing you are a new modder and you started off with this?
  25. Fuganater New Member

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    This is my 6th "mod" but my first scratch build.

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