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Project: Aluminum Water Cooling Case

t_ski

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#2
In the for the first sub :toast:
 
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#3
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:










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





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




 

Funtoss

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#4
How much did all these cost you!?
it looks so nice!
 
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#5
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
 
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#6
The two shelves were cut from a .10-inch thick 5052 via my trusty router, a straight edge and a downcut spiral bit.




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






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




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




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

 
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#7
that is just awsome. I want one!
 
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#8
sub to watch it all unfold. Thanks for the project.

:toast:
 
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#9
Subbed.

That is one huge case.

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

Huge.
 
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#10
That thing will be solid!! Love it :)
 

Wile E

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#13
Hmmm, subbed.
 
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#14
Subbed :) Looks great
 

Blue-Tiger

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#15
Subbed, the model looks soo clean! :D
 
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#16
Next up is to cut the front sheet.




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.




The aluminum bits guided my flush trimming router bit.




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






Now I just need to square all of the corners and cut to width. Ugh.
 
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#17
Another huge case. That is one big radiator you've got there.
 
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#18
subd! this guys projects r EPIC!!! :respect::respect:
 

Chicken Patty

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#19
Subbed, this looks good. :)
 
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#20
more?? pleease!! Loving the fabrication on this project. :)
 
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#21
"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.

 

HammerON

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#22
Sub'd. Glad to see you building another monster case!
 

fullinfusion

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#23
Subbed, this is going to be good :rockout:
 

Wile E

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#24