FEATURED Project Log: Server and Gaming Case

Spotswood · May 22, 2011

The bottom support beams were made from .5x.1-inch aluminum flat bar. I wasn't keen on having to hand drill and tap them, so instead, I routed grooves to accept nuts.

I like this fastening method because its wicked strong and offers just enough "play" for easy assembly.

The frame is bolted to the front inner sheet.

And then the entire subassembly is bolted to the front frame.

hokiealumnus · May 22, 2011

For a wooden case builder, you sure know your way around metal as well!

Spotswood · May 26, 2011

The sides of the HD cage consists of three pieces of .125-inch thick 1x1.5-inch u-channel held together with some threaded bolts. The cage will be bolted to the frame of the case via some .5-inch angle.

The holes in the angle were used to guide the drill bit into the side pieces.

Quarter inch slots were routed out of the u-channels to eventually accept .25-inch threaded rods.

TsunamiJuan · May 27, 2011

I must say, I like your new technique for attaching the frame. Its visually superior in my book, much cleaner looking.

The quality of the work has definately been taken to a new level with this build.

Spotswood · May 28, 2011

Santoprene rubber/plastic tubing was slipped over 1/4-inch threaded rods to form a "cage" to contain the HDs.

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

Parrallax · Jun 1, 2011

I am humbled sir, amazing work!

pwnmachine · Jun 1, 2011

Wow this just gets better every time I see it. :drool:

Spotswood · Jul 1, 2011

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.

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

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.

Spotswood · Jul 14, 2011

I finished the bottom of the HD cage by adding four support beams made from 1x.5-inch u-channels.

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

Spotswood · Aug 5, 2011

Finally managed to mount the HD cage to the case via 12 #6-32 stainless steel socket cap bolts.

onefstsnake · Aug 5, 2011

Very nice!

Always great work! :thup:

Spotswood · Aug 9, 2011

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.

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

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

Spotswood · Aug 12, 2011

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.

hokiealumnus · Aug 13, 2011

That takes some impressive precision getting such thin lines in between the fans by hand. Very well done.

jameseboy · Aug 13, 2011

No other way to say it. Genious.

Subbed

nooster · Aug 13, 2011

i admire how clean your work is! you have more patience than anyone I know so Kudos to you!

i only wish i could manage to have my lines as straight and clean as yours (maybe one day lol).

Good luck and keep up the awesome work!

Spotswood · Aug 13, 2011

The top motherboard tray support is the last piece of the case frame.

Hamscer · Aug 27, 2011

Cant wait for the end result, definitely subscribe worthy!*

MIAHALLEN · Sep 6, 2011

Great work on this one Rich, I really like the concept....do you have any updates?

ctrl_alt_del_ · Sep 6, 2011

Holy crap, you have a gift.

FEATURED Project Log: Server and Gaming Case

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