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FEATURED Brass Tacks: One Day Scratch Build

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Alright frame is almost together. Just have to add the cross bars.


Framealmosttogether.jpg



Breaking for lunch! Man this is physically tough. Back and feet are tired and it is starting to get hot.

1300 PST
 
Frame is complete!


Frameiscomplete.jpg


On to plastic work.

1424 PST
 
3) Cut sheet plastic stock (size to be determined):
Front (#1) 454 mm x 194 mm
Sides (#2, #4) 654 mm x 364 mm
Top (#3) 454 mm x 486 mm
Bottom (#5) 660 mm x 460 mm *** 1/4" plastic
Back (#6) 454 mm x 364 mm
Slant panel (#7) to be worked on later



Plasticcutlist.jpg


Plastic cut list made short work of in 30 minutes by my festool.


It has come to my attention that this case is darn long (654 mm!). Computational error during design? Oh well, better than too short.


1509 PST
 
4) Start on Bottom panel (#5)
Notch corners
Cut shim brass pieces (1/2” trim)
Mount shim brass trim
Mount Bottom panel (#5)


Bottompanemounted.jpg


I decided to nix the brass trim, and notched the bottom panel so that it would sit flush to the square tube.










5) Locate and place motherboard mounts on Panel #5



Motherboardmounts.jpg



Done!

1636 PST
 
First things first:



Dinner with the wife. Hmmm tri tip pot roast no knife needed.




6) Mount Back Panel #6

Locate PCI rack on Back Panel #6
Cut out hole for PCI and i/o rack.
Mount PCI bracket
Cut fan holes




Mounted the back panel and locating the PCI rack:


PlacingPCIhole.jpg









Cutting the hole on my scrollsaw:


CuttingPCIhole.jpg








Hole is correct:


PCIholecut.jpg









And everything fits together:


PCIbracketdone.jpg






I'm going to wait on cutting the fan holes, so that I can do all the fan holes at the same time.



1835 PST
 
7) Start work on Slant Panel (#7)
Cut rectangle, with beveled edges
Cut out notches, with beveled edges
Fabricate mounting brackets
Mount Slant Panel (#7)

Cut fan holes




Slant panel is cut, nice 45 degree beveled edges:


Slantpanelcut.jpg


1949 PST
 
I will answer questions when I've got time!
 
Still going boys--Anyone who knows me knows I'm just getting startin at 2300.



Cutting fan holes



Cuttingfanholes1.jpg


My hole cutter was getting a little janky, so I did this in a 2 step process--scribing the nice circle with the hole cutter.







And finishing it with the scrollsaw:


Cuttingfanholes2.jpg






Fan holes cut:


Fanholescut3.jpg








Next I devised these unusual clips:


Panelclips1.jpg








They are to hold the slant panel in place:


Frontpanelclips2.jpg






2249 PST
 
Anybody still with me? Just hitting my stride.



Frontpaneldone.jpg


Slant panel is done, so done I've even taken off the protective paper.




On to the next step.


0059 PST

Actually I'm going to skip Step 8 and move on to the PSU mount.
 
9) Work on PSU mount
? Threaded rod and brass angle bracket
? Back panel (#6) thru hole



PSUtrapeze.jpg





Well, I call it a PSU trapeze. For layout reasons, I've got my PSU entirely within the case, and I wanted it suspended above the motherboard.







And with PSU:


PSUtrapeze2.jpg







And I think I've officially got to say it. Not gonna happen in one day :cry:


It was ambitious. Maybe on a day with less other things to do, earlier start. I'm gonna tidy a few things up, take a few pics, be back tomorrow. I'd say I've got about 2 hours of work left.
 
8) Complete slanted corners on Side Panels #2 and #4


Done.





Well here are the first day's results:


Firstdayresults.jpg



I'm about 80% there. Summary of what's left:

1) Front panel (mount 5.25 bay, USB unit, switches and LEDs)

2) Mount Hard drive rack

3) Cabling

4) Install



I'm definitely disappointed in not finishing today, but hey, I got a LOT done.


Navig

Good night, off to the showers, maybe a late night snack.

0320 PST
 
Dude, don't torture yourself because you couldn't do it in one day. Most of us couldn't even do a mod properly even in a month (at least, me!)!! So, feel proud of your work!
 
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