1. Welcome to TechPowerUp Forums, Guest! Please check out our forum guidelines for info related to our community.

Project: Server and Gaming Case

Discussion in 'Project Logs' started by Spotswood, Apr 14, 2011.

  1. PopcornMachine

    PopcornMachine

    Joined:
    Aug 17, 2009
    Messages:
    1,563 (0.81/day)
    Thanks Received:
    459
    Location:
    Los Angeles/Orange County CA
    Very nice work. I know nothing about working with aluminum. Like a class.
     
    Spotswood says thanks.
  2. xrealm20

    xrealm20 New Member

    Joined:
    Jan 29, 2010
    Messages:
    467 (0.26/day)
    Thanks Received:
    129
    Location:
    Houston
    Looks awesome dude. Subbed!
     
    Spotswood says thanks.
  3. Thrackan

    Thrackan

    Joined:
    Oct 10, 2008
    Messages:
    3,482 (1.55/day)
    Thanks Received:
    656
    Are you going to line the inside of the HDD cages with some dampening material?
     
  4. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    No plans to do so at this time.
     
  5. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    Santoprene rubber/plastic tubing was slipped over 1/4-inch threaded rods to form a "cage" to contain the HDs.

    [​IMG]


    Here's why the routed slots are superior to individual holes.

    [​IMG]


    [​IMG]

    [​IMG]
     
    TIGR and PopcornMachine say thanks.
  6. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    A last minute design change was to go with SATA backplanes. This required having to route-out 24 phalanx shaped areas for the LED and power cables to pass through.

    [​IMG]


    [These photos are just quick mockups, the perforate aluminum will eventually get mounted to the bottom of the drive cage. ]

    [​IMG]

    [​IMG]


    The backplanes rest on some soft rubber grommets and are attached via two #4 socket head cap screws.

    The 1/16-inch perforated aluminum was a good choice because I didn't have to drill a boat load of holes.

    [​IMG]

    [​IMG]
     
    TIGR says thanks.
  7. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    I finished the bottom of the HD cage by adding four support beams made from 1x.5-inch u-channels.

    [​IMG]

    [​IMG]


    To further dampen vibrations some 1x.25-inch soft foam will be stuck between the beams and the perforated aluminum.

    [​IMG]

    [​IMG]
     
    TIGR and PopcornMachine say thanks.
  8. Sinzia

    Joined:
    Oct 5, 2010
    Messages:
    847 (0.56/day)
    Thanks Received:
    209
    Looking at your aluminum work is like looking at the Mona Lisa, everything's simply beautiful!
     
    Spotswood says thanks.
  9. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    Finally managed to mount the HD cage to the case via 12 #6-32 stainless steel socket cap bolts.

    [​IMG]
     
    TIGR says thanks.
  10. TIGR

    Joined:
    Aug 17, 2008
    Messages:
    2,183 (0.95/day)
    Thanks Received:
    1,029
    Location:
    Minnesota, USA
    Nice work Spotswood. I will watch this project closely.
     
  11. Funtoss

    Funtoss New Member

    Joined:
    Mar 4, 2011
    Messages:
    588 (0.43/day)
    Thanks Received:
    60
    Location:
    New Zealand
    How much more awesome can this get?? dude your work is amazing!
     
  12. puma99dk|

    puma99dk|

    Joined:
    Aug 29, 2005
    Messages:
    3,466 (1.03/day)
    Thanks Received:
    783
    nice, i can't wait to see how it ends out ^^

    erm what hardware r u planing on? ^^;
     
  13. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    Another requirement for this case is the ability to mount six SSD drives. The original plan was to mount them to the bottom of the case, but if there ever was a leak in the water cooling system, all of the SSDs would be toast. So instead, I came up with the idea to mount the drives to the underside of a motherboard tray.

    [​IMG]


    Half-inch standoffs were screwed into the MB tray's existing PEM nuts.

    [​IMG]


    And onto that a .10-inch thick sheet of aluminum was bolted.

    [​IMG]

    [​IMG]

    [​IMG]
     
    TIGR and PopcornMachine say thanks.
  14. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    The front inner sheet was turned into Swiss cheese via 9 holes for the 120mm intake fans. The holes were cut with a 1/2-inch flush trimming router bit, guided by a template.


    [​IMG]

    [​IMG]
     
    PopcornMachine says thanks.
  15. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    The top motherboard tray support is the last piece of the case frame.


    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]
     
  16. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    I spent a full day squaring up the case frame, squaring joints, re-aligning joints etc. in preparation of fastening the sheeting.

    The steps I use to attach a sheet are:
    • Drill a hole in the sheet.
    • Use the hole in the sheet to guide the drill bit for the hole in the frame.
    • Thread the frame hole.

      [​IMG]
    • Countersink the sheet hole.

      [​IMG]
    • Admire work.
      [​IMG]


    The case with the inner front, bottom and lower back panels attached.

    [​IMG]
     
  17. Thrackan

    Thrackan

    Joined:
    Oct 10, 2008
    Messages:
    3,482 (1.55/day)
    Thanks Received:
    656
    This will be so frickin' awesome. I love the detailed touches with sunken screws and stuff!
     
    Spotswood says thanks.
  18. hhumas

    Joined:
    Jun 24, 2011
    Messages:
    553 (0.44/day)
    Thanks Received:
    22
    Location:
    Islamabad
    its awesome ... i am curious to see the final stage
     
    Spotswood says thanks.
  19. erixx

    erixx

    Joined:
    Mar 24, 2010
    Messages:
    3,468 (2.03/day)
    Thanks Received:
    494
    I love aluminium and like your work, very much!

    Only 'but' is : a server doesn't need a big mobo, and a gaming rig doesn't benefit from the heat and obstacles of a neigbouring server in the same case, but i am sure you will solve this!
     
    Spotswood says thanks.
  20. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    My client selected some nice low-profile casters (with 2-inch wheels) which I mounted right away since the case is all nice and square.

    [​IMG]


    Three of the #8-32 stainless steel bolts were screwed directly into the frame via hand tapped holes.

    [​IMG]


    [​IMG]
     
  21. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    I attached the .1-inch thick side and front panels with 6 stainless steel flat head socket cap screws. The front panel extends past the tops of the side panels by .10-inch in order to hide the top's front edge.

    [​IMG]

    The process to attach the panels is:
    • Drill pilot holes along the edges of the panel
    • Clamp the panel to frame and use the pilot holes to drill tap holes into the frame
    • Remove the panel and tap the frame holes
    • Countersink the panel holes

    The side panels extend past the top of the frame by the thickness of the hinge. These will later be scribed and cut to length along the back of the case.

    [​IMG]
     
    MT Alex and PopcornMachine say thanks.
  22. de.das.dude

    de.das.dude Pro Indian Modder

    Joined:
    Jun 13, 2010
    Messages:
    7,891 (4.84/day)
    Thanks Received:
    2,112
    sub'd and that thing is huge. but i guess its small compared to your other builds :p
     
    Spotswood says thanks.
  23. vladmire New Member

    Joined:
    Apr 2, 2009
    Messages:
    118 (0.06/day)
    Thanks Received:
    18
    insane project!

    ---subscribed!
     
    Spotswood says thanks.
  24. Huddo93

    Huddo93 New Member

    Joined:
    Oct 13, 2011
    Messages:
    299 (0.26/day)
    Thanks Received:
    57
    Location:
    Perth, WA, Australia
    Absolutely MAAD build, Sub'd :D
     
    Spotswood says thanks.
  25. Spotswood

    Spotswood

    Joined:
    Sep 2, 2009
    Messages:
    125 (0.07/day)
    Thanks Received:
    170
    Location:
    New Hampshire, USA
    I made the top back plate for three 120mm exhaust fans. Once the back was completed I was then able to scribe and trim the sides to their final depth.

    [​IMG]


    [​IMG]


    [​IMG]
     

Currently Active Users Viewing This Thread: 1 (0 members and 1 guest)

Share This Page