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  1. #41
    Folding for Team 32! Ben333's Avatar
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    Feb 2007
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    New Hampshire
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    Most impressive fabricating skills man! I like the custom made hotswap bay idea too. You wouldn't happen to live anywhere near Concord would you?

  2. #42
    Member Spotswood's Avatar
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    Apr 2010
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    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.


    • Countersink the sheet hole.


    • Admire work.



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

    Rich
    Custom Case Builder

  3. #43
    Member M3dley's Avatar
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    Feb 2011
    Location
    Salt Lake City, UT
    very nice work. adding to my posts so i can keep updated! keep up the good work man.
    + achieva shimian qh270 [2560x1440]
    + asus vn247 [1920x1080]
    + corsair 600T white
    + asus P8Z68-V/GEN3
    + intel i7-2600K @ 3.4ghz
    + 8gb g.skill ripjaw ddr3
    + evga 670 FTW 2gb
    + intel 520 180gb ssd [boot]
    + seagate barracuda 1tb [storage]
    + corsair GS800

  4. #44
    Member Spotswood's Avatar
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    Apr 2010
    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.




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




    Rich
    Custom Case Builder

  5. #45
    Member
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    Mar 2011
    Location
    Bay Area
    GOOD WORK!

  6. Thanks!

    Spotswood (10-11-11)

  7. #46
    Member Spotswood's Avatar
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    Apr 2010
    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.



    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.


  8. #47
    Member Spotswood's Avatar
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    Apr 2010
    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.








  9. #48
    Folding for Team 32! Ben333's Avatar
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    Feb 2007
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    New Hampshire
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    I like the look of really well made homemade cases. More industrial / custom order looking. Kind of like older routers and switches, or those radio shack project enclosures. Are you planning any paint for it or anything decorative? I think bare aluminium would look pretty sleek in a way... not that you can really go wrong with a good paint job.

  10. #49
    Member Spotswood's Avatar
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    Apr 2010
    Location
    New Hampshire, USA
    The hinge for the top was cut slightly undersized and centered with a some old business cards used as spacers.




    Dimples of aluminum had to be removed from the frame in order to make room for the nuts holding the top sheet to the hinge.




    With only a 2.5mm gap between the leaves of the hinge, button head cap screws were used to attach the hinge to the frame.







    The hinge aligns perfectly with the top sheet, which in turn aligns with the back sheet.

    Rich
    Custom Case Builder

  11. #50
    Member joshhua5's Avatar
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    Jan 2010
    Location
    Perth, Westen Austalia
    Subbed, this is amazing

    I have inspiration to create one of these for myself. (No time soon)
    Last edited by joshhua5; 04-28-12 at 09:34 PM.
    The Beast
    OS: Windows 7 64 Bit
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    Ram: 16GB Corsair Vengeance 1600

  12. Thanks!

    Spotswood (04-28-12)

  13. #51
    Member Spotswood's Avatar
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    Apr 2010
    Location
    New Hampshire, USA
    On the bottom of the case, a large slot was cutout which will allow fresh air to enter the front air duct. Following standard operating procedures, a router pattern/template was made at the same size as the desired opening.




    The aluminum was removed with my trusty handheld router in two passes, once with a over-hanging pattern bit and another with a flush-cutting pattern bit.



    Rich
    Custom Case Builder

  14. #52
    Member Spotswood's Avatar
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    Apr 2010
    Location
    New Hampshire, USA
    Up next is fabricating a duplicate of the 120mm back fan panel, but for 140mm fans. This time I had Lazerwerx cut me a custom 140mm fan hole router template out of 3/8-inch thick cast acrylic.



    This template is a snap to use: mark center lines and lay the corresponding slits cutout from the template over them.





    Rich
    Custom Case Builder

  15. #53
    Member Spotswood's Avatar
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    Apr 2010
    Location
    New Hampshire, USA
    The latches for the top are these nice "lift and turn" ones:




    The latches require a fairly small area to be cutout, with only about a 2mm "lip", so I built a very accurate router template from some leftover t-slot extrusion:





    Rich
    Custom Case Builder

  16. #54
    Premium Member #18 txus.palacios's Avatar
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    Dec 2011
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    Cádiz (Spain)
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    Someone, explain me, why am I not sub'd to this mod.
    Last edited by txus.palacios; 08-08-12 at 06:04 PM.
    Maximus V Gene | i5-2500k @ 4.5GHz (ekHF) | 16GiB | GTX470 SLI @ 800MHz (ekFC) | m4 128GB | Arch + Win8
    [ more info... ]


    The only sound I want to hear out of my computer (unless I'm gaming or watching a movie) is the hum of my 6000 rpm fan pushing air through my heatsink. - Seebs
    If I turn up dead, somebody make sure they put "should have just benched in the cold" on my tombstone, along with my most recent superpi32m score. - I.M.O.G.
    I didn't go water-cooling for an air-cooling Vcore!! - bluezero5
    I'll rm -rf /yourface/* - thideras

  17. #55
    Gloriously Lead
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    mbentley's Avatar
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    Basically, I can't think of a reason not to be
    intel i5-750 -- msi p55-gd65 -- 4 x 4gb ddr3 1600 -- msi gtx550 ti cyclone oc 1gb -- antec p182 -- ocz fatal1ty 750w -- windows 8.1 x64
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    forum rules | overclockix | overclockers geforce survey | mbentley.net

  18. #56
    Premium Member #18 txus.palacios's Avatar
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    Dec 2011
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    It surely is! I can't explain how I've not seen this one before!
    Maximus V Gene | i5-2500k @ 4.5GHz (ekHF) | 16GiB | GTX470 SLI @ 800MHz (ekFC) | m4 128GB | Arch + Win8
    [ more info... ]


    The only sound I want to hear out of my computer (unless I'm gaming or watching a movie) is the hum of my 6000 rpm fan pushing air through my heatsink. - Seebs
    If I turn up dead, somebody make sure they put "should have just benched in the cold" on my tombstone, along with my most recent superpi32m score. - I.M.O.G.
    I didn't go water-cooling for an air-cooling Vcore!! - bluezero5
    I'll rm -rf /yourface/* - thideras

  19. #57
    Member Spotswood's Avatar
    Join Date
    Apr 2010
    Location
    New Hampshire, USA
    Drilled two 19mm holes for the vandal resistant switches (power and reset/hard drive activity).

    Using such a large bit (step drill) is a bit nerve racking for me, but with an extra large work surface and some clamps, I manged to get through it.




    Switches!

    Rich
    Custom Case Builder

  20. #58
    Member
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    I wanna see this metal monster at the end of it all
    Intel 4770K
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    AsRock Z87 Fata1lty Professional
    Corsair Obsidian 650D
    Corsair RM850w
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    Seagate 1tb HDD

  21. Thanks!

    Spotswood (08-19-12)

  22. #59
    Fragment85's Avatar
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    Aug 2011
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    Twentynine Palms, CA
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    Seeing anything from the ground up is so amazing,
    Sub'd
    My Linux Experance Blog
    VM-Host - Plague Dell SC1425
    File Server - Sevenseals - AMD 1090T, 16 GB Ram, 19 TB Raw storage, LSI MegaRaid 9280-16i4e w/BBU, in a Norco 4220.
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  23. Thanks!

    Spotswood (08-19-12)

  24. #60
    Member Spotswood's Avatar
    Join Date
    Apr 2010
    Location
    New Hampshire, USA
    During final assembly (before paint) some rework is inevitable. With this case, early on in the build, it was widened to accommodate the front radiators. But I never went back to see if the PSU mounting bracket worked/looked okay. Plus, I never tested the PSU cutout from the back sheet with the the actual PSUs used for the build. Well, the cutout in the backsheet for the PSUs had to be widened by 3mm in order to clear the fan grill on the PSU cooling fan. And the PSU mounting plate looked to dainty and needed to be widened.






    And with the old PSU mounting bracket placed in front of the new one:


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