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[Scratch case] Project Duplex

Discussion in 'Project Logs' started by Ace_finland, Oct 23, 2013.

  1. Ace_finland

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    Hi,

    So this is my new Project for the Cooler Master mod competiton. I still have a bit to design but will start fabricating soon.

    It's called Project Duplex and will be a two faced case.
    -On one side the motherboard, on the otherside a GPU and ssd's.
    -Two seperate loops with a 240radiator each.
    - WIll be made out of aluminum and acrylic
    - Most of the watercooling will be hidden

    Fabricating will start soon!

    [​IMG]
    [​IMG]

    Ace
     
  2. ne6togadno

    ne6togadno

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    what is deadline for contest
    and subed
     
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  3. Ace_finland

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    The dead line is in the end of January, from experience its gonna be a lot of work theese coming weeks :) thx!
     
  4. micropage7

    micropage7

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    looks nice but i dunno how you gonna put flexible pciex cable to the back of the board and creating sleek look. pretty challenging is it?
    subb too
     
  5. Ace_finland

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    It sure is. I will make a cover for the pci-e ports that will hide the cable. The challenge will be to get it look small when irl it will be quite big and bulky. I have ideas in my mind but before i have the actual motherboard i can't do any tests. Hopefullly i will have the motherboard soon.

    And i will get the 20x20x2mm aluminum profile this week!
     
  6. Ace_finland

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    Finally an update! Was a lot harder to get the profile than i thought. Living in the country side has its drawbacks :)

    First i would like to say a big Thanks to OCZ and Mr J. for believing in me and sponsoring me with a 256GB Vector drive. Will take some nice pictures of it as soon as i get it back. Took it to a place to make it fit the build a bit better. More on that in another update :)
    [​IMG]

    The profile, Ordered 2mm thick profile but when i got it it was only 1,5mm. Oh well, would have been nice with 2mm for threading but 1,5mm will be enough.... i hope.
    [​IMG]

    after cutting all the profiles with a hand saw and I milled them to the right angle and size.
    [​IMG]

    De burring all the edges
    [​IMG]

    All profiles except one
    [​IMG]

    Welding it all together. Was too optimistic with the welding. I did not think it would warp as much as it did. All in all it was only a mm or 2 off but due to so many angles and lengths it looked so crooked I did not wanna use it.
    [​IMG]

    Plan B: Cut off all the legs, straighten out one leg that was a bit warped. The rest were fine. Then mill all of the legs at once to make sure they are all the same length and straight[​IMG]

    Decided instead of welding i would make inserts to bolt into the profile and into the base and top. This way it's easier to keep straight and also a lot easier when its time to paint. Should have thought about this before
    [​IMG]

    Tapping the inserts
    [​IMG]
    [​IMG]

    All done. Still need to clean up to get it looking really nice but will leave that until its time to paint
    [​IMG]

    The base
    [​IMG]
    Made a 2mm sheet and pressed it inside the profile, welded it and after milled it straight. If i can get another profile i might make a 45 degree cut instead. Would look a lot nicer.
    [​IMG]

    Time for some sheet metal work. Sticking with 2mm aluminum. Don't know what this is called but it is very useful.
    [​IMG]
    [​IMG]

    The panel is divided into 3 pieces for now while i work with the pieces. I might weld them together at a later stage. Still need to drill a lot of holes and cut some openings in them.
    [​IMG]

    Drilled and getting ready to tap
    [​IMG]
    [​IMG]

    Had to try a mobo on it. Case looks huge and it is a bit big but u think it will shrink a bit once i start adding things to it
    [​IMG]

    Sponsored by
    [​IMG]
     
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  7. t_ski

    t_ski Former Staff

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    I believe that machine is some kind of brake, which is used to bend sheet metal - although that one looks to be hydraulic vs. the manual ones I've used before.
     
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  8. Arjai

    Arjai

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    Looks good. :rockout:
     
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    Crunching for Team TPU
  9. HammerON

    HammerON The Watchful Moderator Staff Member

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    Sub'd. Looks to be a really cool build:)
     
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  10. Ace_finland

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    Yeah, it was a hydraulic one and was a dream to use :)

    Thx buddy!
    Thx man!
     
  11. a_ump

    a_ump

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    i see how you could manage to get it to look neat now, your first post sketchings made the case seem like it'd be a lot smaller, or my perception is just a little off lol. Cool build
     
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  12. Ace_finland

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    I might have changed the sizes a bit :D After further drawings i realised i was making something impossible :) so i added a bit of lenght here and there :)
     
  13. Mindweaver

    Mindweaver Moderato®™ Staff Member

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    It's a press brake, I've got one at my shop. :toast:
     
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    Crunching for Team TPU
  14. Ace_finland

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    You are correct!


    So a very small update. Have been busy helping mum and dad move house, so have not had any time for modding but picked something up on Friday that i thought i would share with you.

    My first part for the build, a 256GB Vector drive.
    [​IMG]

    Content: SSD, a mounting plate, screws, a sticker, a manual and a key for acronis true image
    [​IMG]

    The drive, looks great but didn't really fit the black and red build i'm doing. so decided to make some minor changes.
    [​IMG]

    Didn't wanna go too crazy with these as i want it to look enough original but still fit the design
    A solid black one, this was very hard to photograph, probably took 50 photos and didn't get a single good one. Need to read up on how to take proper photos :)
    [​IMG]
    [​IMG]
    [​IMG]

    A black metallic one
    [​IMG]
    [​IMG]

    Made enough stickers so i have a few to mess up, or if i wanna make a small raid :D
    [​IMG]


    Sponsored by
    [​IMG]
     
  15. t_ski

    t_ski Former Staff

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  16. Ace_finland

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  17. Ace_finland

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    Hey guys,

    Finally an update!
    Recently bought a house and have been moving things (mostly to the garage) so now i can start modding more and close to home so updates should be more frequent now

    After thinking a while about the front and the back panel i decided the best way would be to have them water cut, i have countless times milled thin aluminum sheet and it usually ends with the flute snapping. Still need to cut a lot of holes in the back panel for all the connectors but i will do that at a later stage
    [​IMG]
    [​IMG]

    One step forward two steps back, or however the saying goes. I wasn't very happy about the shape of the frame and the quality of the work i had put in it so i sat down and re-drew the frame and decided it was time for plan C. This time it is made from a 10mm aluminum sheet, it's 15mm wide. I changed the angles a bit and shortened it a bit length and depth wise, the width it still the same
    [​IMG]

    Time to drill some holes
    [​IMG]

    One drilled, one to go, hopefully it fits!
    [​IMG]

    Time for some threading, i always use the cordless drill to tap with, so far i have never snapped a bit with it and its so much faster.
    [​IMG]

    Had to change the "shape" of the mill so i could drill and tap the support bars
    [​IMG]

    The support bars
    [​IMG]

    Done
    [​IMG]

    Seems like it fits!
    [​IMG]

    So much better than the other frame, a lot of work but now i like it and it won't bug me anymore.
    [​IMG]

    Bottom plate for the frame, drilled and counter sunk
    [​IMG]
    [​IMG]

    Perfect fit except one hole which i need to file a bit.
    [​IMG]
    [​IMG]

    Old vs new, i don't know what you guys think but i like the new one a lot more
    [​IMG]

    New part arrived!
    [​IMG]

    Another box in the box
    [​IMG]

    Everything is very well packed
    [​IMG]

    Lots of cables with it, needs some sleeving though
    [​IMG]

    Love the brushed steel look on the top of it
    [​IMG]
    [​IMG]
    [​IMG]

    Scale photo
    [​IMG]

    More updates coming soon!

    Very sad news about OCZ, the only SSD's i've owned are OCZ and i have been very happy with them.
    Sponsored by
    [​IMG]
     
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  18. SaiZo

    SaiZo

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    Yupp, it's a press brake, NC controlled by the looks of it..
     
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  19. Ace_finland

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    Hey guys!

    Finally all moved in to the new house and got internet up and running again.

    Just a short update but another one hopefully this weekend.
    Milling the motherboard plate and the Gpu plate. Only milling the shape for now and doing all the holes and cutout later.
    [​IMG]

    More milling and drilling, these are for the other panels on the side. [​IMG]

    All slots cut out
    [​IMG]

    As i haven't had any access to the press break for a while I started looking for an "affordable" sheet bender, but the quality on them are horrible. So i decided to take a different approach to bending the sheets.

    60 degree V-flute, 1mm in the bottom
    [​IMG]

    Milled a 1mm deep slot in both panels
    [​IMG]

    Clamped it to the desk with the slot facing upwards
    [​IMG]

    Put a small flat bar across the sheet so i would bend it equally everywhere
    [​IMG]

    Worked a lot better than i thought it would.
    [​IMG]

    Test fit of the panels. Had to try the grommet too to see if i made the hole the right size
    [​IMG]

    More panels.
    [​IMG]

    Also made a cut out for the motherboard in HDF, It's a lot faster and easier to redo if i have some measurements wrong :)
    [​IMG]
    That is all for now, hopefully another update over the weekend!

    Sponsored by
    [​IMG]
     
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  20. Ace_finland

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    Back with an update, was supposed to be a bit earlier but have been sick so haven't had much time. Anyways...

    Did the motherboard and GPU side in aluminum
    [​IMG]
    [​IMG]

    Test fit of components
    [​IMG]
    [​IMG]
    [​IMG]

    Made some covers for SSD's so the cables will be hidden. No pictures of the installed yet but there will be soon enough
    [​IMG]

    Same for the Pci-e extension cable
    [​IMG]
    [​IMG]
    [​IMG]

    Made a sheet for holding the rads and fans. Decided to make it in two separate pieces, one for each rad.
    [​IMG]
    A bit of bending
    [​IMG]
    Test fit
    [​IMG]

    Time for some acrylic. This is for the front panel. Was a bit tricky before i figured out how to make it in two runs. Milled some holes and put some centering axles in it. worked out pretty well.
    [​IMG]

    Installed. Made it slightly bigger so i can sand it to the right size. Still need to do the rear and top and bottom. Still not sure if it will be painted or led lit. But i will need to decide very soon.
    [​IMG]

    That's it for this time

    As you can see i have some new parts :) Will do some unboxing as soon as i can get it set up

    Sponsored by:
    [​IMG]
     
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  21. adulaamin

    adulaamin

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    Looking really good! Can't wait for your next update! :toast:
     
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    Crunching for Team TPU
  22. Ace_finland

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    Thx buddy!
     
  23. McSteel

    McSteel

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    Wow, this has some serious potential, and looks to be coming along quite nicely! I like.

    As for the acrylic, I'd go with LEDs along the edges. But use some dim/soft ones, with a wide cast angle (maybe 60° or so), and serious bonus points if you manage to have a potentiometer somewhere to be able to control the intensity or even completely turn the lighting off.

    Just my .02

    Keep up the good work! :)
     
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  24. ST.o.CH

    ST.o.CH

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    It´s looking very nice, and if you could turn the ssd lettering in the right position it will be better:rockout:.
     
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  25. Ace_finland

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    Thx buddy! I have some red power leds i'm gonna use. Guess why i have a fan controller on each side with 6 pot's each and only 4 fans :D I will divide the leds into sections so i can fine tune them all so they have the same brightness :)


    Thx buddy! I have made gloss black and mettalic black stickers for the SSD, they should be in a previous update. So it will be the right way once its done :)
     

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