Water Cooled Framer Project

[Navig]

Hi all,

My latest project is well underway. Altho this portion of the ocforums seems to have sputtered out since being subsumed by the Cases section, as I have traditionally done, I will post here. Also, as I have traditionally done, my most in depth worklog can be found at the abit forums. (http://forum.uabit.com/showthread.php?t=140838)



The DIY Watercooled Framer Project


1) DIY - This is a going to be a Do-It-Yourself type project which means several things. Easy to obtain materials, tools, and techniques. Like my DIY Benching Station (http://www.ocforums.com/showthread.php?t=528477): Simple, cheap, functional, and reproducible.


2) Watercooled - I recently took the plunge into watercooling. (http://www.ocforums.com/showthread.php?t=559028) This case is designed to house multiple radiators and loops.


3) Framer - I have frequently built my cases with fully supported frames, with hung plastic panels (example: frame made with lubic components (http://img.photobucket.com/albums/v363/navig/Lubic%20Tall/Frame1.jpg) hang some plastic panels. (http://img.photobucket.com/albums/v363/navig/Lubic%20Tall/blackpaneled.jpg))

I'm going to put little twist on this one. For this project, I want the support frame visible--kind of like an exoskeleton.



.

[Navig]

As usual, I start with some concept sketches:



http://img.photobucket.com/albums/v363/navig/Sketches/Dualradcase4.jpg

I plan to have this case be double wide, putting the 5.25 drive bays and hard drive rack side by side. This will allow for side-by-side radiators at the top or bottom of the case.






http://img.photobucket.com/albums/v363/navig/Sketches/Dualradcase5.jpg

As I mentioned before, I'm going to inset my plastic panels, thus exposing the frame elements.




.

[Navig]

Here are some layout pics:


http://img.photobucket.com/albums/v363/navig/Sketches/Dualradcase1.jpg

The motherboard will be upright, and floating down the middle of the case.






http://img.photobucket.com/albums/v363/navig/Sketches/Dualradcase3.jpg

The motherboard tray will thus bisect the case. The compartment above the mobo will have dedicated airflow. The compartment below the mobo will house the psu and watercooling elements.






http://img.photobucket.com/albums/v363/navig/Sketches/Dualradcase2.jpg








I originally conceived of this case being for two 2x120mm radiators with 2 completely separate loops. The watercooling elements could thus be arranged something like this:

http://img.photobucket.com/albums/v363/navig/Sketches/Dualradcase6.jpg



Also, as you can see, the overall shape of the case will be a fairly standard double wide rectangle, but I will be adding a sloped edge--which will probably house the switching panel.




.

[Navig]

Since I do have spare lubic component laying about, I decided to make a general mock up of what I had planned. Note the case will NOT be made from lubic components, but rather standard 3/4th square aluminum tube.

However, using lubic components helps me get a grasp on sizes and general layout. Also general stability of such a large frame.





http://img.photobucket.com/albums/v363/navig/Framer%20Project/Frontandslopepanels.jpg



Here is the overall concept so far. The dimensions of this mockup are not quite correct: it will be more narrow (I didn't feel like cutting up lubic bars just for a mockup).

The frame elements will be mostly exposed. The downside to having inset panels is that you lose access to the frame internally. And while you can mount things directly to the plastic panels, for stability its better to mount it to the metal frame. For this reason, the bottom and back panels will be surface mounted, while the sides, front, and top inset mount to expose the frame.


The other element I'll point out is that I wanted to add a little architectural interest to the case, rather than being a straight cube, I broke up the front edge with a sloped panel.




.

[Navig]

Front components sit like so:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Frontbays.jpg








Plenty of space for radiators (2 rows at the bottom and/or 2 rows on the top):


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Frontleft2.jpg







Internal components will sit roughly like so:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Trayposition3.jpg







Some more component possibilities:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Trayposition1shelfframeequipped.jpg






The double wide nature of this case lets me put the psu behind the motherboard, good space also for watercooling components.

[kyleboy77]

holy hugeness! I'm interested in seeing how it turns out

[911us]

Very interesting !...can't wait for the result.

[Navig]

Now that I've got a general construction design, its time to convert it to stock materials. The bars are easy enough--I'll be using 3/4" square aluminum tube (available at most hardware stores, I picked it up from onlinemetals.com).

The one critical piece to constructing a frame is NOT readily available from any hardware store I know of. And that is a 3 way corner bracket. This is what comes with the lubic kits:




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Cornerbracket.jpg


However, it's really not beefy enough for my tastes, and again not available for purchase.




Fabrication of such a bracket is fairly straight forward for any professional machine shop. This thread here from bit-tech (http://forums.bit-tech.net/showpost.php?p=1583317&postcount=2) really perfectly outlines the concept of a beefy 2 hole per leg bracket.

I have in fact got a machine shop designing such a bracket for me for bulk quantities. But instead of waiting around for them to mass produce for me, I thought I'd give a shot at my own hand-crafted version.




First I started with some 1/4" bronze tinted plastic (I had leftovers from my previous Jewel Box Project (http://forum.uabit.com/showthread.php?t=139566)):


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Plasticbracket1.jpg


These brackets are based on a 2 1/2" length, 1/2" width bracket, which will actually expose the metal frame even at the corners.






Cut and holed:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Plasticbracket2.jpg







Glued together:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Plasticbracket3.jpg









And fit to some square tube:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Plasticbracket4.jpg

[Mother Goose]

This is going to be pretty cool, man. Can't wait for the updates.

[Navig]

Here is the basic concept of how this frame will be bracketed together:

The frame is made from 3/4" aluminum square tube, and the corners are double mitered to come together at the 3 way corners, which will be bracketed by my custom brackets:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Cornermitercuts_1.jpg







Mounted like so:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Cornerbracketmounted.jpg

[Jolly-Swagman]

Lookin Dam good there,,,as always Navig

[Navig]

Here are the all the basic elements to the frame: bars n brackets.




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Squaretubemitered.jpg

[Navig]

And a little side note. Here are 3 sample chips from delvie's. What color do you think for the panels:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Paneltestcolordarkblue.jpg

Dark blue.











http://img.photobucket.com/albums/v363/navig/Framer%20Project/Paneltestcolorlightblue.jpg

Light Blue.












http://img.photobucket.com/albums/v363/navig/Framer%20Project/Paneltestcolororange.jpg

Orange.

[Mother Goose]

And a little side note. Here are 3 sample chips from delvie's. What color do you think for the panels:


I'd say the light blue. The dark blue and the orange are a bit much if it's going to be the entire panel.

[cabose1227]

I like the orange, you may not be able to see throu well tho.

[spyderdixie]

I hate blue in a case becouse all the lights are blue now. But that being said, the dark blue looks good. What if you use more than one color?

[OldSkool]

I'll second Light blue and also subscribed. This promises to be awesome!

[KosAMD]

ORANGE! Blue is overdone tbh.

[Navig]

A whole lotsa tapped holes later, and wapow! there ya go!



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Framecompletewithorgans.jpg




Got some mockup components in there for size reference. This IS a big case, with big panels. Think I'll stick with subtler colors, probably the light blue. I could maybe work multiple colors, not sure how to make that look nice and keep it simple.

[cabose1227]

Looks very well thought out, great design.

[spyderdixie]

hey navig, why dont you get a wire welder. As much alu. you mess with, it would save you a boundle in brackets.

[Jolly-Swagman]

I'll second Light blue and also subscribed. This promises to be awesome!


Yeah +1 for the Light Blue and also subscribed

[Navig]

About the welding, yeah I get that a bit. Just remember I'm really pretty much a novice when it comes to this sort of shop stuff. Until the year before the last, I was modding in my KITCHEN. I'm completely self-taught, and my most expensive tool is my prized $130 plastic cutting saw blade. Which is why most of my mods aren't really that technically difficult--hence "DIY".

I'm not sure I could teach myself to weld. Shop and metal working classes are on my life's to-do list.



Next stop--internal framing.

[spyderdixie]

you will never learn if you do not try.

[Mother Goose]

ORANGE! Blue is overdone tbh.

Depending on your decor, an all-out orange paneling might be too much. Blue IS cliche, though.

Don't have any other options other than those three?

[spyderdixie]

you could go with 2423

[Clockwork_Apple]

Looks huge...

first page in a navig log :D

[Slayer2003]

I've been thinking of building a tube-framed case lately...may have to take some queues from you Nav. ;)

One thing that bugs me though....all this metal is gonna be quite heavy after it's assembled. And I see you're using acrylic brackets. Aren't you worried about stress cracking?

[spyderdixie]

slayer, he is useing hollow alu. tube. It will be pretty light.

[Navig]

It's quite light, as mentioned this is 1/16" wall thickness aluminum. So far I can reach out and lift the frame with my arm outstretched without even straining myself.


The acrylic corner brackets were not my first choice, if you read above. I'm still waiting for a machine shop to fabricate me some metal ones. However, it is hi quality 1/4" acrylic--properly bonded (I use IPS weld #3), its pretty strong.



I'll comment on the overall strength of the case. As seen in the last picture, its has pretty good stability. When bracketed together in a full structure, it maintains its integrity quite well. Certainly strong enough for computer components, but probably not strong enough to support human weight.

It is a very large case. There is some torsional wobbling if you work the long axis corners. I do have plans to stiffen the case up. The framework to mount components and panels is going to double as cross bars to add stability. Finally, when you lock the panel pieces into place, it should be quite rigid. Unfortunately a little bit of wobble is inherent in such a large frame with big wide open panel sides.


navig

[spyderdixie]

once you put the acrilyic in then it should stiffin up a good bit

[Navig]

Here's the subframe, which acts as a shelf for the 5.25 bay rack, the psu, and the motherboard tray:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bareframecomplete1.jpg








Here are some pics on how the components will sit:






http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bareframewithcomp3.jpg


As I mentioned the subframe holds up some components, creating a space below it for a radiator.








Back:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bareframewithcompback.jpg













Side:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bareframewithcomp4.jpg












Front:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bareframewithcomponents1.jpg

[Kasm]

Looking awesome, another good project to show others what can be done with some imagination and skill.

[Navig]

Rails at the top and bottom will hold radiators:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Upperradiatorrail.jpg











Here's a little strength and stability test. It's a decent frame, strong and light:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/th_Stabilitytest.jpg (http://smg.photobucket.com/albums/v363/navig/Framer%20Project/?action=view&current=Stabilitytest.flv)

[gangaskan]

this is pretty neat navig :) i think i'll have to subscribe to this!

[SeanBest]

That beast is HUGE. Sure it's gonna look awesome when it's done. Keep up the posts!

[spyderdixie]

subscribed

[EmAn]

Its been a while since I have seen this pop up. Nice work and I wanna see you keep 'er goin

[sandyduff]

wish i could build stuff... i have a habit of cutting and burning myself... and thats just me attempting to cook!! :D

[Navig]

I was shopping radiator grills, but the prices just got to me. So I poked around my shop and found all the necessary stuff:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Grill1.jpg




Expanded aluminum mesh, 1/2" aluminum trim (1/16" thickness), some 3/8" corner braces, screws, washers, and nuts.



Bang bang drill drill and about an hour later:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Grill2.jpg


The remaining holes are for mounting it to the panel.

[cabose1227]

:drool:That grill looks really cool!!!!!!!!!!!!:drool:

[Navig]

Stock plastic sheets arrived courtesy of Delvie's plastics:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Plasticpanels.jpg






Cut my side panels:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Sidepanelscut.jpg








Bottom and back panels have been cut to sit flush:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bottompanelcomplete.jpg

[Navig]

Rest of the panels have been rough cut and loosely put into place. Starting to look like a real case!




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Panelscomplete1.jpg







http://img.photobucket.com/albums/v363/navig/Framer%20Project/Panelscomplete2.jpg








http://img.photobucket.com/albums/v363/navig/Framer%20Project/Panelscomplete3.jpg

[Jolly-Swagman]

Coming together there nicely Navig !!

[gangaskan]

that is pretty damm slick :)


keep up the good work navig :)

[Navig]

This week, I went at the next major technical hurdle: tool free removable motherboard tray.




First I cut the tray itself from 1/4" acrylic:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/mobotrayrough1.jpg





Its positioned, so I could cutout the back panel portion of the tray:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/mobobackpanelcutout1.jpg






Which I cut out with the scroll saw:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/mobobackpanelcutout2.jpg





Next steps:

1) Cutouts for the i/o and pci cards, fans, and access to the backside of the mobo

2) Aluminum trim pieces

3) Aesthetics--brushed the aluminum, flame polished the plastic.





And here's the result:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/mobotraycompleteempty.jpg








You can see the backside here; the nice big cutout allows for access to the back of the cpu socket. Very nice!

http://img.photobucket.com/albums/v363/navig/Framer%20Project/mobotraycompletebackside.jpg

[Navig]

Here it is mounted up in the case:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Mobotraycompleteinstalled2.jpg







And here is the finished backside:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/mobotraycompleteinstalled3.jpg








The beauty of this tray is that it is held by only thumbscrews. Here's a little boring video of me demonstrating how to remove the mobo tray:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/th_Mobotrayinstall.jpg (http://smg.photobucket.com/albums/v363/navig/Framer%20Project/?action=view&current=Mobotrayinstall.flv)

[gangaskan]

thats pretty slick i like it :)

[Navig]

A little bit of drawing:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/PSUcutoutplacement.jpg






A little bit of sawing:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/PSUcutoutscrollsaw2.jpg







A little of bit of fitting and trimming:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/PSUcutoutfitting.jpg







Add the trim, and now I've got a psu port:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/PSUcutoutcomplete.jpg

[sekai]

keep up the good work, i had a similar plan but i faild epicly at it ><

anyways, i find it very interesting and imo this is gonna be great MB cooling xD

[Navig]

Here is my proposed airflow design:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Fanplacementplan.jpg

[Navig]

Here I've fitted, trimmed, and hardmounted the left panel.

There are 7 small screws holding it down--I'm considering thumbscrews so that it could be removed tool-free.


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Leftpanelmounted.jpg

[Ben333]

Navig, looking awesome! Nice work :beer:

[Navig]

Here's a pic of one of the more tedious tasks that is going on.

I've decided to brush the framing bars. One at a time, I go ahead and dismount a bar. First I dremel down any significant gouges. Then I sand it with 220 grit paper, first in small strokes to work away any scratches and smooth the dremel marks. Then in long strokes to get the brushing. Finally I use a sand paper jig to get perfectly parallel long strokes.


Here in this pic you can see that I've brushed the long vertical foreground bar. The left pic is the bar before, and the right is after:




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Brushcomparison.jpg

[Navig]

This also another tedious task. The large plastic panels need to be fitted to the frame (which is slightly--by mm--off from square). So I mask off a portion of the corners (see the masking tape), and dremel (sanding drum) away 1-2mm to make it sit proper.



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Plastictrimming2.jpg

[Navig]

Both blue side panels are trimmed, fitted, finished and mounted:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Plasticrightpanelcomplete.jpg




Better news yet--I've finished brushing all 13 aluminum bars. So the pace should pick up on this project.

[Rattle]

very impressive

keep up the good work

[baggedmazda]

it would look way better tig welded up maybe you can talk to a welding shop around or even a high school shop teacher( i live down the block from one and when i want something realy pretty i stop by and he lets me use there massive tig welder not realy too hard to do). i would also polish those bars up they would turn out better than chrome. but realy bad ass case

[Navig]

One day I plan on learning how to weld. On the other hand, it's nice to know I can take my powered screw driver and completely disassemble this case into a small box and a few sheets of plastic in under 5 minutes. Also makes replacing parts or altering things a snap.

I like the brushed look because frankly it hides scratches. This one's meant to mostly be a functional case, so I don't really want to be worried about a scratches on a perfect finish. Might consider powder coating it. Don't get me wrong, tho, I do like shiny (http://img.photobucket.com/albums/v363/navig/Acrylic%20clean%20cabling/Shinyplacard.jpg) objects. (http://img.photobucket.com/albums/v363/navig/Lapping/Allendalelap.jpg)




Went to work on cutting my holes for the radiator:




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bottompanelmarked.jpg








Weapon of choice: circle hole cutter.



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bottompanelholecutter2.jpg









And there you go!



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bottompanelmounted-1.jpg

[baggedmazda]

it helps me to have my whole works facilitys to use i have benders, cutters tons of great tools. and of course there was a push by me to get a water cooled tig in but its not there yet maybe it will come in soon.

[Navig]

Me, I've got the basement of the apartment we're renting. Better than the kitchen, where I started.




New set of holes for airflow to the motherboard:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bottompanelfinished.jpg








The radiator holes get some gasket sealing:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bottompanelgasket.jpg





I should mention that the radiator and its fans are mounted to the frame itself--for obvious reasons it shouldn't be moved (as it will eventually be connected by water filled tubing to the motherboard). The panel merely has holes to let air pass thru--the panel can be easily removed without tinkering with the radiator.

The airflow fans, tho, don't weight much, and can be easily disconnected, and so they mount directly to the plastic panel.






From the bottom:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bottompanelcompletedandmounted-1.jpg








And on the inside:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Bottompanelcompletedinterior.jpg

[Moto7451]

Nice work.

You can find the brackets you used on the corners in the lumber section of Home Depot and Lowe's usually. They're made of galvanized steel so you'll have to do some work to make them pretty but they do exist.

[Navig]

Went to work on the upper panel, which has the same general layout as the bottom panel:





http://img.photobucket.com/albums/v363/navig/Framer%20Project/Toppanelcutouts.jpg







Here I added on the trim and fans:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Toppanelassembled.jpg



Since the top doesn't need dust filtering, I used a nice little grill I constructed from aluminum and modder's mesh.









Mounted up:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Toppanelmounted.jpg

[Navig]

Here it is in place:





http://img.photobucket.com/albums/v363/navig/Framer%20Project/Toppanelairflow.jpg








And a little illustration to redemonstrate my airflow concept:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Toppanelairflowlabel.jpg

[air00]

nice work, do you know about how long it took and about how much it cost??

[Navig]

I probably put in around 4 hours per week on this project. It's been what about 10 weeks now, so that would be about 40 hours. That seems a little short maybe 50 hours now.

The cost is in the range of $200.

I should be done in maybe 3 more hours of work technically. That is I will be done with a complete ready-to-be-sold case only.

It'll probably take another 10 hours to set up all the fans, fan control, and install a real system with my water cooling loop.

navig

[Navig]

Put together my hard drive rack:




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Harddriverackinstalled.jpg




This is comprised of a Lian Li 6 drive rack topped with a 3 drive rack, both available at performance-pcs.

There are 4 screws in the bottom mounting it to the bottom panel, plus the bracket near the top portion that prevents it from swaying.







Then I carved out the last panel, the front panel:




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Frontpanelcutout.jpg








And with the fans added and the 5.25 bay:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Frontpaneltrimmed.jpg

[Navig]

Well, the shell and all the major structural components are complete. I decided to step back and take some overall pics to show how far I've come:





http://img.photobucket.com/albums/v363/navig/Framer%20Project/Panelscompleteleftfront.jpg








http://img.photobucket.com/albums/v363/navig/Framer%20Project/Panelscompleteleftsquare.jpg








http://img.photobucket.com/albums/v363/navig/Framer%20Project/Panelscompleteback.jpg







http://img.photobucket.com/albums/v363/navig/Framer%20Project/Panelscompleteright.jpg







http://img.photobucket.com/albums/v363/navig/Framer%20Project/Panelscompletefrontright.jpg







Next step: Switching panel and lighting.

[jamesman32]

That is so damn sexy.....Great work Navig. I wish I knew how to do that, and had the skill, or the money to beg you to make me one :beer:

[Navig]

Added some tabs to firm up this panel:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Centertabs.jpg






http://img.photobucket.com/albums/v363/navig/Framer%20Project/Centertabs2.jpg





This panel needs to be nice and stiff because I'm going to put my switching panel here. You want a nice firm push to the buttons, without any give.

[Navig]

Here is my first stab at lighting this monster:




Unlit:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Lightingtest2.jpg









Lit from the side:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Lightingtest1.jpg




I've got 2 12" white ccfls, mounted up top and down bottom. With the big panels, it comes out nice and evenly lit.









http://img.photobucket.com/albums/v363/navig/Framer%20Project/Lightingtest3.jpg

Altho in contrast to the light blue side panels, the other panels are still semi-translucent.









http://img.photobucket.com/albums/v363/navig/Framer%20Project/Lightingtest4.jpg


This back half has a smaller 4" white ccfl to light up the psu, back of the mobo. Also, the watercooling components (rez and pump) will be here.

[Jolly-Swagman]

Looks Awesome Navig,, well done and the lighting is perfect.

[rxtrom]

You Sir are an extremely motivated and visionary person. I think most case builders are..the ones that finish that is.
Modding is a 2 hour, maybe weekend project, but building requires pure skill, talent, and devotion. Which reminds me, how do you pace your self to only work on it for 4-5 hours a week. If I am working on something I am pedal to the floor and it consumes me. Hence the wife limiting my projects.

[Navig]

I love what I do. Experience helps me pace myself appropriately--if you count my benching stations, I've completed something in the range of 20 scratch build projects. To pace myself I set a minor goal that'll take me approximately an hour (for example, arranging the ccfls with tape).

I also multitask, so I always have 1 or 2 1 hour tasks sitting about in my head. As I've mentioned, I'm also simultaneously working on 2 scratch built benching stations.

So for example, on this evening's agenda I have 2 1 hour tasks in mind. For this project, I plan to paint my ccfl invertor boxes, and to possibly hard-mount the ccfls in their appropriate spots. For my station project, I plan to cut my main mounting boards and set them up for routing.

My next 2 steps would be to wire my switching panel (that'd be a 2 hour task).

So on and so forth. I've usually got about 4-5 next steps laid out in my head. The trick is also to know when you've got to order stuff. So for example, I know I have enough tasks to occupy me for another 1-2 weeks, but I'll have to get on ordering some watercooling equipment soon.


navig

[Navig]

And so, here are the painted invertors:





http://img.photobucket.com/albums/v363/navig/Framer%20Project/CCFLinvertor.jpg






I used vinyl dye. Who decided baby blue should be the original color?

[Navig]

Well, I've been a little busy of late. Traveling, and a bit of a push to finish some benching stations.


The pace should pick up, as I plan to finish (and have a fully running q6600 system) running before the holidays.


Mini update:



Sleeved and installed my CCFLs.



http://img.photobucket.com/albums/v363/navig/Framer%20Project/CCFLsprepd.jpg






Next, I will wire up the CCFLs to their switch, as well as install and wire up my switching panel.

[AngelEyes]

Magnificent!

[Sam__]

this thing is awesome, another great case navig.

[Navig]

Working on the switch placement:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchpanel1.jpg


Going with 2 lit vandals and a toggle. The first vandal has a white LED which will be power-on. The second vandal has a purple LED which will be hard drive activity. The toggle will turn on/off the internal ccfls.



And installed:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchpanel2.jpg



I wanted to place the switches to line up with the 120mm fan intakes below. But now that I look at it, I think I should have clustered them a little closer.

[Navig]

Now that I've got the buttons in place, I've been struggling on how to wire this beast up.

Every panel is translucent, so there is a 360 degree of view of everything inside. Which means cabling must be squeaky clean, or it will look cluttered. Not only that, this case is enormous, so standard lengths of wire to the switches (and ccfls and fans) aren't going to cut it.






http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchcableroute1.jpg




Regarding the switches, I must get route 10 wires (2 for the ccfls, 2 for the power switch, 2 for the reset switch, 2 for the power led and 2 for the hdd led) from the red arrow to the blue arrows.

You can see that I started to string out some wire, having it hug close to the bracketry.

[Navig]

And then it dawned on me. I've got a completely disassemble-able frame made from tubular aluminum. Why not route the wires right through the frame?


The first step was to remove the necessary frame bars and punch some holes into them:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchcablerouteholes.jpg


The light blue arrows point to the holes I punched out. The red arrows indicate where the bar originally came from. As you can see, this would be nearly impossible without being able to disassemble the frame.








The holes were made with: good ol' nibbler tool, then sanded to a dull edge:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchcableroutenibbler.jpg

[Navig]

Finally, I threaded a test wire through the whole route:





http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchcableroute2.jpg



The detail is a little hard to see, so I've highlited it, then terminations indicated at the arrows. I'll probably terminate with some quick disconnects, so that the panel can be removed easily if necessary.

As you can see, again, this wouldn't be possible without disassembling the frame. The vertical bar is unattached and that is the only way to thread the wire thru the 90 degree turns.

And there you go. Completely hidden wiring!

[MadMan007]

Wow that's sweet. Minor question but what did you use for a gasket to seal the fans against the case in post #61?

[gangaskan]

Wow that's sweet. Minor question but what did you use for a gasket to seal the fans against the case in post #61?

looks like some type of weather stripping to me :) not sure if its a foam or rubber variant, more or less rubber.

[Navig]

I order so many things from mcmaster, thank goodness they keep a record of my past orders.


mcmaster part#93085K671
Adhesive Back Foam Rubber Bulb Seal 3/8" O'all Width, 7/32" O'all Height, 10'Length

[MadMan007]

Thanks. I figured it was some sort of weather stripping but bulb seal sounds cooler :) I was mostly just curious.

[Moto7451]

Awesome case. I may do something similar in terms of construction for my next case build.

[Navig]

Good luck. I think a pretty big theme to this build is that it is mostly DIY. I'm using only basic power tools and widely available parts.






Here are some pictures illustrating how I work my internal wiring:





First I built a wire bundle. There are 3 bundles comprised of 22 AWG wire. The first contains the 2 leads to the CCFLs and the toggle, the 2nd contains 4 wires to the power switch/power LED, and the 3rd contains 4 wires to the reset switch/HDD LED.

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Cablebundle.jpg








I feed it thru the small end holes at the bottom of the case, down the horizontal bar. The vertical bar has been displaced so that I can grab the end as it comes thru. Then I send it up vertically thru the vertical bar.


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Cablefeed1labeled.jpg








It comes out this small hole at the level of the top horizontal bar, then I send it down to the exit holes:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Cablefeed2.jpg








Finally, I can re-mount the vertical bar and pull the wires taught:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Cablefeed3.jpg








I decided it wouldn't be a good idea to have the cables running thru these fairly sharp holes in the aluminum, so for the bottom hole, I made a little plastic trim tab:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Trimbezel.jpg





Which goes here:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Cablefeedplastictrim.jpg






For the holes at the top, I might also make a trim plate, but I also have some rubber pass-thru's in the mail I might try. I can't really finish the wiring until these arrive and I decide.

[Navig]

Okay, finished up the wiring in this corner of the case:







You've got to be careful about finishing the wiring. Dozens of wires, multiple layers of mesh and heatshrink, rubber gromets have to all be assembled in the correct order.

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchpanelfinalwiring1.jpg








And here is a quick pic of the final product:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchpanelfinalwiring2.jpg





Nice, simple and understated. Generally I want the wiring to not be noticed, leaving the overall image to be clean and tidy. But when you start looking for the cabling, you're going to realize it is truly hidden.

[Navig]

Here's a little trick I've used to build a fan multiplier.



Here I start with a standard easily available pci pass thru bracket:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Fanmultiplier1.jpg






Trim the edges:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Fanmultiplier2.jpg





Add a top cover and mount:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Fanmultiplier4.jpg







And here it is in the case:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Fanmultiplier5.jpg





As you can see, its very unobtrusive, yet has plugs for 6 fans (as you can see I will be using 2 for the inflow fans, and 4 for push-pull on my 2x120 radiator). Furthermore, I don't have to do any sort of crazy modifications to my fans--simple standard 3 pin terminations.






.

[MARCI]

That is SEXY

[Navig]

Okay, now I've moved onto the wiring on the backside of this case:



Here you can see where the wires for the upper CCFLs and the fan multiplier for the upper bank of fans enters the frame:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Wiringbacksidetop.jpg











http://img.photobucket.com/albums/v363/navig/Framer%20Project/Wiringbacksidebottom2.jpg

And here is where they exit.

I'm going to mount several terminations (upper fan multiplier, lower fan multiplier, and ccfls, probably even the power connections for 5.25 devices and hard drives) on the underside of the panel that supports the psu (which has been removed in this picture). This is a nice place, close to the psu, yet tucked away and hidden.









Here I am testing the connections. Just look at that tangle of wires, and you can see what kind of wiring harness I'm building (and trying to cable neatly).


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Wiringtest1.jpg

[Navig]

And here is my first test of the fully wired and cleaned cabling for the CCFLs:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/CCFLsframelit.jpg








To give you an idea of what this took, I hilighted all the wires for the CCFL system here:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/CCFLsframelitlabeled.jpg

[Navig]

I quickly slapped a few of the panels back on to give you the effect I was trying to achieve:





In the dark:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/CCFLstestunlit.jpg









Then lit up:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/CCFLstestlit.jpg








And a real time video of that action:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/th_CCFLtest1.jpg (http://smg.photobucket.com/albums/v363/navig/Framer%20Project/?action=view&current=CCFLtest1.flv)

[Navig]

Starting in on details now.




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Switchpanelconnect.jpg

Linked up all the wires coming from the switching panel to the wires from the motherboard panel. Used an 8 pin psu interconnect.








I mentioned before that I was going to use the space underneath the PSU support panel to organize cables: these are nice "p" shaped cable clips:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/PSUcableorganization.jpg








And here are some stacks of fans I've got to sleeve!

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Fanstack.jpg

[Elluzion]

what is the best way to sleeve fans???

I am a fan of everything you have done! this is great. probably one of my dreams/goals someday. to actually build my own case, have control and mod everything. it would be amazing.

Everything looks great!!!! :D


keep it up

[Navig]

"what is the best way to sleeve fans???"

Since you ask, and since I'm sleeving a bazillion fans, here you go:

3 pin fan cable sleeving guide. (http://www.theraptorpit.com/forum/index.php?showtopic=3242&st=0&gopid=54065&#entry54065)




navig

[Pylet Lyght]

Very nice wright up!

[Navig]

Okay, finished sleeving and installing this bank of fans.

That's six fans crammed together, with easy access to disconnect any one.


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Sixfansbottombank.jpg

[Navig]

And here is the upper bank of fans:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Topbankfans.jpg






I had to take this radiator from my first watercooling loop. (http://www.ocforums.com/showthread.php?t=559028) Don't feel bad for this system--since I took off the watercooling loop, its now sporting a Thermalright Ultra 120 copper. (http://img.photobucket.com/albums/v363/navig/Framer%20Project/Lubicdualtowerthermalrightcopper.jpg) This heatsink rivals decent watercooling, both in performance and price.

I should mention, that this project will progress a little slowly over the next week, as I am going to take the time and review the Ultra 120 copper. Then the q6600, IP35-E, and G80 8800gts will migrate to this case.

[Navig]

Here is my resevoir/pump column:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Rez-pumpcolumn.jpg







And here it is installed, as viewed from the backside (of the motherboard):

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Rez-pumpinstalledback2.jpg






Angled view here, you can see it sits in the half of the case, in the plane of the radiators, behind the motherboard:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Rez-pumpinstalledback3.jpg






However, it is seen from this side also, but will allow me to route my tubing behind the motherboard:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Rez-pumpinstalledfront.jpg

[Pylet Lyght]

O_O its looking AWESOME.

[hokiealumnus]

Man that looks good Navig...have you decided which system you're putting in it?

[Navig]

For starters: G0 q6600, OCZ ram, G80 8800gts.

There is that Corsair HX620w in the background, I'm not entirely sure it will be powerful enough to power all these fans and pumps.

Looking for a large hard drive (this machine will probably serve as a media center).

Watercooling: That's a Laing with a PTS top, and an EK resevoir. I've got a Apogee GT and and a MCW60--my next step is to lap them. For tubing, I've got some braided 1/2" / 3/4", but it is really stiff. I may go for just regular tygon.

[hokiealumnus]

Watercooling: That's a Laing with a PTS top, and an EK resevoir. I've got a Apogee GT and and a MCW60--my next step is to lap them. For tubing, I've got some braided 1/2" / 3/4", but it is really stiff. I may go for just regular tygon.
FWIW, Raymo uses this stuff (http://www.frozencpu.com/products/8276/ex-tub-433/PrimoChill_PrimoFlex_PRO_LRT_Tubing_716ID_58_OD_wi th_332_Wall_-_UV_Blue.html?tl=g30c99s809); says it bends rather easily and never kinks.

[Navig]

I like the aesthetics of feser black flowing thru braided tubing. Plus I already have both braided and non braided tygon. But if I have to order something else, I'd prob go with the primo thinner.

[Navig]

Very difficult to photograph 2 lapped units in one picture, so its a bit fuzzy. But still a joy to behold:



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Blockslapped.jpg



The blocks are unpolished. I used up thru 800 grit, then hit with a bit of 2000 for shine.

There is a bit of uneven-ness around the thru-holes on the apogee.

[Navig]

So for tubing, here are my 2 options:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubing1.jpg

Standard tygon with black anti-kink coils. Looks classy.











http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubing2.jpg

Braided tubing.

[hokiealumnus]

I you're asking for opinions, my choice is A) Standard tygon with black anti-kink coils, for the stated reason.

[Navig]

And so it is! The braided stuff was just way to hard to work with. It wouldn't kink, but neither would it bend at all! Even with a scalding hot water bath.

So here you go:




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubingcomplete1.jpg








And a little zoom on the loop:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubingcomplete2.jpg








And the backside:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubingcomplete3.jpg







The circuit is as follows: pump, radiator, cpu block, radiator, gpu block, resevoir, pump.

[AlucardCasull]

That is looking awesome,the black coils look great. I am suprised that is not done more often. btw, the way you powered the fans with that external pci thing is genius, will definitly steal that idea if its cool with you!

[hokiealumnus]

That really is beautiful work. The pump/reservoir column is icing on the cake. Its positioning and the way it looks is...well, I've run out of adequate descriptors. Bravo.

[Jolly-Swagman]

Yeah the tygon tubing with black anti-kink coils, looks real sexy,, and classy too,, Well done there Navig

[Navig]

Alright, my little side diversion is complete:

Thermalright Ultra Copper vs. eXtreme. (http://www.ocforums.com/showthread.php?t=591890)


Now the components are freed up to move ahead with this project, so it is back ON!



First I decided I wanted a bracket to help hold up the tubing, so it wouldn't be resting on the motherboard.





First I took a rectangle of plastic and drilled out some 7/8" holes:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubinbracketfab1.jpg








Then I bisected them:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubingbracketfab2.jpg








Polish and mount:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubingbracket.jpg









And here it is doing its job:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Tubingbracket2.jpg

[Navig]

Now its time to add some water to this project:


Here is my fill mechanism.

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Fillmechanism.jpg







I did have a bit of leakage. Turns out I reassembled my mcw-60 block incorrectly. Easily fixed!

Also somewhat instructive. If I need to drain the system in the future, I've discovered that I could easily dismount the mcw-60. It is then free with enough slack to drop it out the back-bottom of the case (see pic below) and put it in a bucket. Then crack the seal on the sink and it will drain the entire system at a controlled rate.



Here is the system actually leak testing.

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Leaktest.jpg





Had to move this behemoth upstairs, its a bit cold here in Boston. Subzero might cause some damage.

[Navig]

A bit of a delay--took the time to set up mini-shop upstairs to escape the cold Boston winter.


Just a few details to work thru:




Finish up the front side wiring. This is a good place to hide cable clutter:




http://img.photobucket.com/albums/v363/navig/Framer%20Project/Frontwireshide1.jpg

Underneath the support plate for the front 5.25 bays.





After the 5.25 bay rack is set in, you can't see this cable clutter at all:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Frontwireshide2.jpg







Last details:

1) Build my custom SATA power connectors.
2) Clean the cable clutter at the backside (at the power supply).
3) Get a new hard drive.
4) Install the components.

[Navig]

Going to use the scraps of all the other fans I trimmed for sleeving to build a multi-head cable for the DVD drive and hard drives.


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Multiheadcable1.jpg

[Navig]

Also worked on #3 on the to-finish list. Not that I'm advertising, but a certain (pretty much only remaining) B&M electronics store has Seagate 1TB 32mb cache 7200rpm drives for $99.

[Insane Scyth]

Looking awesome, keep up the good work!

[Navig]

Custom SATA power cables are complete:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Customsatacables.jpg

[Navig]

First round of basic cable installation and cleaning, and this case is complete, ready for installation!




Main side view:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Roughfinishrightangle1.jpg






Another angle from this side, with the lights on:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Roughlitrightangle1.jpg







The front:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Roughfinishfront1.jpg







The workings behind the motherboard:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Roughlitleftangle1.jpg







The back panel:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Roughlitbackangle1.jpg








I was going to save these type of pics for when I installed the components, but I couldn't help making a preview:



Here the case is complete with the blue side panels on:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Roughfinishsidepanels2.jpg








And with the lights on:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Roughfinishsidepanels1.jpg

[Jolly-Swagman]

Just two words describe this wonderful project Navig,,, Sheer Elegance !!

[Drew1Down]

i LOVE this project, but my only concern is the mobo tray, does your mobo mounting holes double as grounds?

[MARCI]

Nav, you have another winner on your hands, great work

[Navig]

Getting ready to transfer in some real components.

All modern motherboard I've worked with ground thru the PSU. I've been running plastic or wooden cases since around year 2000, never had a grounding problem.

[Kayden]

When do you start taking orders? :santa:

[Navig]

So let's start installing some components!


First I started with the completed but empty case:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Installstart.jpg









A dozen screws taken out in seconds (with a powered screw driver) and the side panels come off:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Installstart2.jpg










Put the motherboard on: around the backside you can see that I have a cutout that allows me access to the mounting back plate.


http://img.photobucket.com/albums/v363/navig/Framer%20Project/Installmoboback.jpg








Hook up the cpu block!

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Installmoboin.jpg

[brwnfldl]

WOW!:drool: I would pay good for you to make me on of those

[Navig]

Now the video card I had some problems!




If you take a close zoom at this pic here:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Installvideocardfiasco3.jpg



You will notice that I'm using a swiftech MCW60. If you know your watercooling, you will also notice that I've got the G80 mounting bracket attached. Which was unfortunate because I am trying to install a G92 8800gts!

So here's the kicker. The only way to replace the bracket is to REMOVE the block completely from the loop--the screws for the bracket actually hold the block together, and the bracket cannot get past the block anyways.

So how does one remove the block from the lowest point on a loop. Well I could drain the entire loop, rebuild, and then re-fill.



Or, thanks to the sturdy and easy access design of my beautiful frame project (pats self on back), I tipped my case forward. With some slack from the gpu loop tubing, I could now convert the video card block to the HIGHEST point in the whole loop:


http://img.photobucket.com/albums/v363/navig/Framer%20Project/InstallVideocardfiasco1.jpg








Which means I can safely take block apart!

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Installvideocardfiasco2.jpg

Remember, as I'm taking this picture this is at least 2L of distilled water in the system!







After that little fiasco was taken care of, installing the video card was as simple as hooking up the block.

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Installvideocarddone.jpg





Finally, I dropped in the hard drives, and plug in all the necessary cables and wires:

Hold you breath and hit the power on!



http://img.photobucket.com/albums/v363/navig/Framer%20Project/Installturniton.jpg

[Daedalion]

Just read through this build...absolutely awesome, I wish that i had the skill/time to develop the skill to make something like this

[fast96se]

that thing is sick

[Navig]

Alright, last set of pictures for this thread.





http://img.photobucket.com/albums/v363/navig/Framer%20Project/Completecrtangle3.jpg









Lights on:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Completecrt3.jpg









Different angle:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Completecleftangle1.jpg









Again, lights on:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Completecleft1.jpg










Without the side panels on:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Completerightmid2.jpg








http://img.photobucket.com/albums/v363/navig/Framer%20Project/Completeleftangle1.jpg











Front view:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/Completefrontangle2.jpg








And finally, a video demonstrating the nice contrast of lights off-lights on:

http://img.photobucket.com/albums/v363/navig/Framer%20Project/th_Completelightingtest.jpg (http://smg.photobucket.com/albums/v363/navig/Framer%20Project/?action=view&current=Completelightingtest.flv)







The system is 100% running, cpu and gpu folding.




What's next for this project?

As is my tradition, when I complete a log type thread, I usually start a new thread titled "Completed".

I convert my spare bedroom to a photo studio and take some publication quality photos, and post them plus a recap of the concept and construction, in the "completed thread".

I do have a few niggling details to take care of. I got my power and HDD led's mixed up. I need to clean up and tuck away the 24pin atx and pci-e cables. Finally, I'll probably change out the cpu waterblock to an Apogee gtz I've got in the mail.

And finally I have named this project (instead of the aluminum frame colossal box thingy that I've been calling it):




The Navig Exoframe Project!


navig

[hokiealumnus]

Beautiful work Navig, stunning attention to detail. Bravo!

If you haven't already decided you're going to submit this one to CPU for the mad reader mod, you should. I've heard you've been in it before, but it would be nice to see your creation in there now that I have a subscription. :)

[x30Jx]

Navig... you are a GOD.
This case is simply amazing.

I am hoping to attempt to reprduce it; can you tip me on how get those awesome vertexes where the aluminum tubes meet? Or any other tips/tricks?

Thanks
Joe

[Navig]

Did you mean how I cut the aluminum to a tip?
I simply cut the aluminum with a chopsaw at 45 degrees with a fine trim blade. I've seen folks also use a miter box with a hacksaw, if you don't have power tools.

If you mean the brackets themselves, I hand cut them from 1/4" plastic with a scrollsaw (you could do it with a jigsaw), then glued them together.

This was a real time worklog, so I included lots of tips on how I did things. Please feel free to ask me specifics.

navig

[x30Jx]

Well it is mostly the aquistion... I cannot seem to find some stuff like clear motherboard trays, Hdd or DVD cages, or Front Panel IO stuff (USB, Audio, Status lights....), and I would also really like to see some dimensions on that beast, as I am aiming for a much smaller 12W x16H x16D and I would like to see a sense of scale.

Also, can you possibly give me a rough sketch-out of your watercooling loop(s)? I cannot quite follow it(them).
Again, thanks for anything you can tell me.
Joe

[fusion509]

wow that is amazing! Nice custom case!

[Navig]

Sorry, it's odd, I guess I never linked to my competed thread.


-->> Completed Exoframe thread. (http://www.ocforums.com/showthread.php?t=597792) <<--




There are a lot more pictures and explanations in the thread.

For example, this thread explains my wc circuit here. (http://www.ocforums.com/showpost.php?p=6005350&postcount=7)


Nobody really makes plastic motherboard trays (clearpc.ca or even myself could construct you one). Here is where I put some pics on the construction:

Motherboard tray construction here. (http://www.ocforums.com/showpost.php?p=5807348&postcount=46)



A lot of stuff miscellaneous pc stuff I get from performance-pcs. You can find things like front USB ports, especially among the Lian Li replacement parts tab.


Come to think of it, I didn't really list my sources at this thread, so I will add that to this and the completed thread.




Performance-pcs
Mountain Mods
Jab-tech
Petrastechshop
svc

mcmaster-carr
onlinemetals
Delviesplastics
Home Depot
Lowes


I get a lot of minor components from performance-pcs. I get pretty much all my hardware, screws, brackets etc. from mcmaster, and my plastic from Delvies.

navig

[fusion509]

what was the total cost of you case?

[johnnyyork]

Hi Navig. I've been comtemplating a new build for a much roomier solution to my cramped case. I've thougt about using wood frame. But after searching for days for ideas, I came upon this project at 2'clock in the morning and was like "holy crap...thats perfect!".

Your case layout (i've viewed all of this thread and completed thread) is awesome. Very well thought out.

I have a question. I've used miter cuts in wood working for joining. However, I've never used a double miter cut to join three frame members. I know I could look it up, but I was wondering how you did it since this is a DIY project. Maybe you have some tips to map it easier.

Thanks!