OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #41
The top divider was next.
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Project: EVGA Classified SR-2 Case
- Thread starter Spotswood
- Start date
- Joined
- Feb 21, 2005
- Location
- Boston, MA
That is fantastic work. Gives me inspiration to start a similar project. From doing mill work, I can only imagine how much time you have invested into this.
Whereabouts in NH are you, if you don't mind me asking?
Whereabouts in NH are you, if you don't mind me asking?
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #43
Thanks. I'm down here in Nashua.
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #44
Cutouts for accessing and viewing the inside of the top case were routed out of the side panels. I was able to re-use two router template jigs for the cutouts, although one had to be mod'd to reduce the width of the cutout.
Threaded inserts were installed in order to attach removable plywood covers over the cutouts.
My next task is to build a shelf to fix that droopy motherboard tray.
Threaded inserts were installed in order to attach removable plywood covers over the cutouts.
My next task is to build a shelf to fix that droopy motherboard tray.
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #45
I've been sick all week, but a few days ago I did manage to bang-out a simple support for the motherboard tray.
Ugh, now I need a nap...
Ugh, now I need a nap...
- Joined
- Feb 1, 2009
- Location
- Illinois
Looks very nice! No more droopy!
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #47
I managed to spend a few hours in the shop this morning working on fastening the top divider to the case itself. But just like everything else on this case, nothing is fastened permanently, which meant I needed to install some more threaded inserts.
The divider is attached to the side panel's solid oak rails:
The divider is attached to the side panel's solid oak rails:
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #48
Even the most mundane aspects of a build often require many small steps in order for them to come out just right. For example, in this build the fastening of the side panel covers required having to accurately transfer the locations of several threaded inserts to the covers, which was accomplished by first screwing in some button head screws into the threaded inserts.
Followed by taping a cover perfectly centered over the cutout. And then using a deep throat clamp, transfer an impression of the button head screw into the backside of the cover.
Lastly, with all of the fastening and unfastening of bolts into and out of the threaded inserts, some of them started to become loose. After testing many types of glues, the best method for fixing the loose threaded inserts was to flood the area with Cyanoacrylate glue. Blue painters tape with punched-out holes was used to prevent getting glue everywhere.
Followed by taping a cover perfectly centered over the cutout. And then using a deep throat clamp, transfer an impression of the button head screw into the backside of the cover.
Lastly, with all of the fastening and unfastening of bolts into and out of the threaded inserts, some of them started to become loose. After testing many types of glues, the best method for fixing the loose threaded inserts was to flood the area with Cyanoacrylate glue. Blue painters tape with punched-out holes was used to prevent getting glue everywhere.
Last edited:
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #50
Completed the upper case's bottom.
All holes are 140mm and the covers allow tubing to pass to/from the lower case.
All holes are 140mm and the covers allow tubing to pass to/from the lower case.
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #52
I re-assembled the radiator stand. Its simple yet elegant with its industrial kick *** looks.
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #53
I made another router template (the last one for this project!) and cut-out the holes in the bottom case's side panels for the radiator intakes.
- Joined
- Feb 1, 2009
- Location
- Illinois
Radiators look nice. Like you said, simple, yet elegant. Really turning out nicely!
- Joined
- Jan 28, 2010
Whoaa, this looks just great! Very nice work Spotswood !
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #56
I've been working on the case doors, which has been a time consuming task consisting of cutting the 6.2mm-thick oak veneer plywood down to a rough size and then thickening them by gluing strips of 1/2-inch thick birch veneer plywood.
The panels are trimmed to their final size (less 1.5-inches) and then 3/4-inch square solid oak strips are glued to the edges of the panels to hide the plywood veneers.
The panels are trimmed to their final size (less 1.5-inches) and then 3/4-inch square solid oak strips are glued to the edges of the panels to hide the plywood veneers.
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #57
Any unevenness of the plywood trim was quickly dealt with on the jointer.
The doors also function as huge airducts so blocks were glued around the perimeter of the door to offset the door away from the frame of the case.
The doors are attached to the case via a dead-simple "post and hook" mechanism. The post consists of a #8 socket cap screw, 1/4x1/4-inch aluminum spacer fastened to the case via a threaded insert.
The hook is a slitted piece of .125-inch aluminum flat bar attached to the blocks on the door via more threaded inserts.
The doors also function as huge airducts so blocks were glued around the perimeter of the door to offset the door away from the frame of the case.
The doors are attached to the case via a dead-simple "post and hook" mechanism. The post consists of a #8 socket cap screw, 1/4x1/4-inch aluminum spacer fastened to the case via a threaded insert.
The hook is a slitted piece of .125-inch aluminum flat bar attached to the blocks on the door via more threaded inserts.
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #58
With the fabrication of the lower case essentially complete, its on to finishing...sanding, staining and applying wipe-on polyurethane. With a large piece like this, its essential (for me anyway) to be able to apply finishes comfortably, which I can do sitting down by using a homemade turntable.
The turntable is just the undercarriage of an old office chair.
The turntable is just the undercarriage of an old office chair.
- Joined
- Jan 17, 2003
- Location
- Centennial, Colorado
Absolutely phenomenal construction quality! An incredible project so far, I hope who you are making it for will provide build pictures or at least some finished pics with it populated 
OP
- Joined
- Apr 5, 2010
- Location
- New Hampshire, USA
- Thread Starter
- #60
Thanks to all for the comments.
With the final finish applied to all surfaces the bottom case is now 99% done (its missing the bottom molding, which I won't apply 'til the very end).
Front:
Side:
Top:
Obligatory closeup:
With the final finish applied to all surfaces the bottom case is now 99% done (its missing the bottom molding, which I won't apply 'til the very end).
Front:
Side:
Top:
Obligatory closeup:
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