Case Mod - In Progress Project: PrometheusCU - Update #54 - May 28 2010 - Video Teaser

iv never seen networking done that way between two machines. is this networking old school com port style?


the weekend is here Langer, get modding and give us are fix!

 

@MrWizard Thanks for the support.

@x06jsp Cheers!

@Burnout21 Actually the serial->usb cable will only be used to read/write any changes to pfSense on the CompactFlash card. The Pico will still be networked via cat5.

As for progress, I just got ready for the day ahead. I'm clad in work clothes and off to the garage.
On the agenda for the day is to plan/fabricate the prototype radiator mounts and "skirt" that will elevate the machine about 3.5" off the ground, giving the rad room to breathe.

I think I'll also post some of the "engineering diagrams" that will be engraved throughout the case tonight; simple little illustrations that should give a 'manufactured for the masses' feel.

I should have a pretty big update early next week (Wednesday hopefully) as I'm meeting with my machinist on Tuesday. My plan is to finalize the design of the parts that need to be routered out, then cut some tests out of 1/8" aluminum, or wood, perhaps even plexi.

 

Let us begin.

I've finished the rad mount prototype.

I started with a 40"x40"x1/8" sheet of used aluminum.
This panel was once used in the fabrication of Carbon Fiber sheets - the aluminum panel are used to help form the carbon panel. The carbon is cooked in a heated press at ~40,000tonnes. After a short while, about 100 carbon panels, the aluminum develops imperfections and heat stains - It's then thrown away. My Dad runs the Carbon Fiber plant so over the years I have developed a rather large collection of these aluminum sheets.


After a bit of rough cutting with the trusty jigsaw I did some light filing to clean the cuts.


Then onto bending


The final product, minus the holes.


Once that was complete I checked the fit - luckily the "measure 5-times cut once" methodology continues to work for me.


A side view, note also that the final bends will be much more precise. I plan on having 'V' shaped groves milled into the copper plate where bends are needed to ensure accuracy.


Then I had to drill precise holes in the the chassis.


From there I did a test fit. (Note that the final design will include slots for airflow, I'll post an illustration later today.)
Almost perfect, I eyeballed the holes in the rad mount prototype and a couple were off slightly. No big loss though because the final product will be machined precisely.


Thanks for reading! More to come this evening.

 

Another update for you guys, but there will be more to come this weekend.

I've finished the tray prototype that will both house the radiator, and lift Prometheus 3.5" off the ground.

We again start with some aluminum plate. As you can see I've marked out the areas to be cut.


Like the above post, I've put the jigsaw to work.


After using the dremel to crudely score the bending lines I put the piece in my bending brake.
This is what I came up with


A close-up of the joints.



Then a test. Perfect Fit!





And here is how it sits right now.
In fabricating these parts I've realized that the final design will need to seat the radiator about 1/4" lower. As you can see from the pics, I haven't left enough room for the front rad fan to breathe.
But that's why I made these prototypes... to narrow in on design flaws such as that.



That's all the fabricating I'll be doing today, tune in later this weekend and I'll have some illustrations posted.

Thanks for reading!

 

HAHA, awesome work mate!

the bottom going to be anodised black to match the case?

 

If your changing the serial connector why not just buy a gender changer? And dont you mean change it to a female connector?

 

@MixWizard I'm taking it apart regardless, because the wire and housing are going to be replaced to suit the aesthetic of the rest of the project, so I figured that I might as well just remove the existing serial connector and replace it with one of female gender (it is female, thanks for the correction). This is just one of many many, many, modifications to wiring and hardware that I'm planning. Prometheus will be more than just a case mod... it will be a hardware mod even more so.

@Burnout21 Hahaha, well done. All the parts that you see me roughly fabricating from aluminum will be machined from 99%pure copper plate by the time this mod is finished.

 

WTF with the tape I want to see the real work man. You are doing good job with the Alum Well done

I don't know what to see now. I have to see more work

EDIT: that is a real Copper? or paint?

 

Nice case the lian-li is a good choice.
All the work done with the aluminum plate are very nice

 

Mate its lookin uber good even by now only. Nice placement of wares, real clean.

 

@ComputerKing - Thanks. All the aluminum pieces are prototypes (most people would use cardboard, but I have time and a lot of extra aluminum). I'm using tape because I've not yet purchased the mounting hardware, so I don't know hole placement.

In the next few weeks I'll be replacing all the aluminum panels with CNC cut copper plate anyway; so the aluminum is not a huge focus (hence the crude cuts/bends). Everything that you see there is solid copper - not paint, not plated - and eventually there will be LOTS more of it as I have a 4'x8'x1/8" sheet of 99% pure copper plate on delivery from MetalSupermarkets.

@Nolimited - Thanks! Lian-Li is the only choice as far as I'm concerned. I've owned about a half-a-dozen PC-60 series cases.

@acey - Thanks mate, much planning was required to get all the pieces to fit together. By the end you'll see that I plan on almost all the space.

 

OH YEAH Langer THE KING OF COPPER is here, Dam man that sounds promising. I can't wait to see.

 

Hmm almost thought you had an entire thread dedicated to me.

Ha.. right.

The case looks excellent so far and I would be scared to mod something like that. Looks expensive with all that copper.

 

Dude, those alu plates gonna be copper colored?

 

@ComputerKing - Hahaha, thanks!

@PrometheusCon - Awesome handle man, happy you like the mod.

@acey - It wont just be copper coloured, the aluminum will be replaced with precision machined copper plate.



A small update for the masses.
Here is an idea of what a couple of the copper components will look like.
From left to right - Front Facade Panel, Top Exhaust Fan Grill, Radiator Grill/Mount. I'll post the designs for the rest of the pieced some time tomorrow; along with some of the illustrations that I'm going to have engraved throughout the case.

black = cut
grey = engrave
dashed = bend
*click for supersize*

[edit]Added a a 'jagged edge' to the front facade. Since the touch panel LCD covers the traditional front air intake I will need to mill slots in the side of the front panel to act as air intake. The jagged edge will make space for these intake slots. The slots can be seen in the initial design concept illustration[/edit]

Thanks for reading! Tune in soon for more.

As always, crits are welcome and appreciated.

 

WOW this really is something!

I honestly never liked that special edition case, however what your doing with it has changed my mind. Love the attention to detail, it's very very impressive work. Precision cut copper part too.....another WOW!

Watching this very closely

 

Nice. I think we can all agree no corners will be cut on this mod. Keep up the great work!

 

Heya just to say looking good but still not sure why the amd processor if your building a performance pc :S

 

DUDE that is Pimpin!!!!!! lol even you will write the names on it. That is kickass!!!

 

This is awesome.
Couple questions:
How are the hard drives going to be distributed between the Pico and the main system? If the Pico is acting as a server type thing, will most of the storage be on there?

Why do you have the firewall attached to a wireless adapter when you have cat5 going to it anyway?

And didn't I see on the eeeforum that you were getting Skulltrail?