Scratch Build – Complete Cygnus X1.

How do u bend your alu in this brake:


?

Do you heat it before bending or something?

 

thanks for sharing your ideas in DIY bending machine!

this mod is sweet

 

That's not the brake, just a vice with some kind of jaw protectors. He mentioned using the vice for the side tabs for that pic. I imagine he just uses brute force for those (ie a block of wood and mallet. Correct me if I'm off here.)

Hey oldnewby,
Nice again! I'm curious to see how the rest of this will turn out. Will you be doing anything more than running wires in that cavity beneath the mobo tray? Any lighting plans?

Bad break on the bending problem (excuse the pun). Do you think it would have been possible to avoid this if you'd changed up the order of the lines you bent, or was the distance between bends just too small?

 

Thanks exitus.

Haha., Thanks Jipa, if you can lift it you can have it.

The Boy 4rm oz., Thanks again.

No, just bend it over.

Anytime nocturnull.

Thanks ModMinded.,
Just wiring inside the cavity, but yes I will have lighting in this one.
In regards to the bending problem, no there was no way to do it
in the bender.

 

I expected to have this done yesterday but all didn't go as planned.

So just need to cut three pieces of 12mm square tube to join the two
halves of the mobo/drive trays to each other.





Some drilling and tapping.



I used some 304 dome socket screws here.



And that's it together but still needs a little more cutting, filing and shaping. The tabs will be made
into a more pleasant shape and some of the bends need tweaking.

 

Unfortunately a few problems popped up.

I was reasonably happy with the brackets at the top but after thinking
about it for a while, and taking into account how this secures the backplate,
mobo tray and fan carrier/internal front panel together at the top, the
decision was made to remove the brackets and make a bigger one out of
a separate piece of metal.

This turned out OK considering the distortion from the bend and removal
of the brackets here.



But when measuring up against the back panel it just wouldn't fit.
Soon it became apparent that the small bend that I couldn't make in the
bender was the culprit. It was out by 3mm from front to back.



I couldn't think of a way to fix this and still have a presentable finish so I started
it over with the same basic design but just a different way of getting there.
The PSU cover would now be separate as will the top bracket. By making the PSU
cover this way I can accurately bend it in the brake.







The old on the left and new on the right.



Unfortunately there is a lot less room for cables, but hopefully enough.



And this time it all fits very well.

 

No words come out.

John

 

Very clean, very smooth, very nice.

 

Awesome!

 

Looking very nice!

 

More more more! Hehe!

 

Nice. I like the idea of a central mounting point. The outside could be made with almost anything that way, like a funnycar dragster.

 

Thanks for the replies.

A few problems. See post #26.

Yes, that's why I can worry about the shell later.
Also I may build more than one.

 

freaking epic!
I like the way how you've built the internals of the case, so it wouldn't have to have much support from the cast itself.

 

Fitting the back panel.
This is made from 3mm plate.





Although you can see dome sockets here they will be replaced with countersunk socket heads.



The tabs are fixed with dome nuts. All the fittings are 304 Stainless.



Now I need to make a panel to support two 120mm fans, I/O ports and switches,
and the top support bracket.



This is what the new top bracket looks like.



I'm very happy with this new version, it all fits just right.
I'll be back soon.

 

This is really coming together nicely, excellent work my friend.

 

Takes a brave modder to show the OOPS to the internet. That last picture of the top with the crossed out mistake is great. This attention to detail is very nice
John

 

Thanks boy 4rm oz.

I wish that was the only mistake., at least this one wont take three days to fix (see post 26).

 

Last day of a three day break and got a fair bit done today.

The top support cut and filed.



And tabs bent in the break.



The inside front panel laid out on 2.5mm sheet.



Cut and filed.





And now we can see a little of what it will look like.

 

Nice workbench you have there mate, everything you'd ever need.