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Old 24th Sep 2012, 19:02   #21
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Quote:
Originally Posted by FatPandas View Post
You could use the plastic from an old ring binder and cut it to the same shape and just epoxy it on. It'd give a professional finish and serve a purpose.
I am not sure to understand this one (sorry not to be native English speaker)

I think I will go with electrical tape
Thanks for the tip.
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Old 24th Sep 2012, 19:18   #22
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I think he means take plastic from one of these:


And then glue it on to the aluminum.

I was thinking electrical tape myself... depends on whether or not it will be seen, I guess.
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Old 25th Sep 2012, 13:15   #23
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Quote:
Originally Posted by Ch2pa View Post
Thank you



The solder points are actually very close but not in contact. There is no tracks on the surface of PCB in contact with the aluminium support, so I think it won't be shorted.

Do you have any suggestion for a cheap, easy to find material I can use to insulate the support? (I will have the same issue with the GPU holder)
I know in the US there is liquid electrical tape, this stuff works great for say hard to reach places and it goes on thin and you can do multiple layers to ensure coverage, and takes up almost no space.

I do have to say that I am very impressed with how you keep lining up the grain on your pieces, I am jealous of your dads shop I used to work in my grandfathers shop he had all kinds of tools. Keep up the good work and I look forward to seeing more.
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Old 25th Sep 2012, 17:20   #24
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Thanks for the explanation Mosquito

Quote:
Originally Posted by Mechh69 View Post
I know in the US there is liquid electrical tape
I live in France but I may found this "liquid tape".

I will think about this insulation and give feed-back asap

Quote:
Originally Posted by Mechh69 View Post
I do have to say that I am very impressed with how you keep lining up the grain on your pieces,
Thanks. Actually I thought to this since the begining. When I cut the flanks, I kept the off cuts and reused it, providing identical grain.

Quote:
Originally Posted by Mechh69 View Post
I am jealous of your dads shop
Yeah me too.
I wouldn't have done this mod without his tools.
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Old 26th Sep 2012, 10:40   #25
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loving the idea mate
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Old 29th Sep 2012, 07:42   #26
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Thanks redd13!

This week I received another command:



Fan and thermal paste!

And the processor, an Intel Core i5 3450S:


I am now able to test the system, I will report soon.
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Old 4th Oct 2012, 17:40   #27
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Update of the week (actually the last week, I am a bit late on this one)

So last week I received the CPU, it was time to assemble and test the configuration (even if I still miss the SSD and GPU).
First step: mount the processor.



That was the easy step.

Second step: mount the Hyper 612s.
I screwed the two fixations on the heatsink base:


then mounted the heatsink on the motherboard and tightened it with the backplate.


And here it is:



In the rush I forgot to plug the DDR3. Fortunately, the fan can be removed from the heatsink very easily.

I plugged the PSU, HDD, keyboard, mice and screen:


and it boot. or not. It scared me while I was trying to figure out what was wrong. Hopefully it was just the power switch which was dead so I just striped its wire to get a direct contact and it finally boot.

I installed Seven on the HDD to check if everything runs fine.
I still need to install the drivers and some updates and then I will do some benchmark and stress test (mainly to check CPU temperature).

Later on saturday I worked a bit on the case. The front panel cover gluing process is a success:


I started to create the plexiglas cover for the leds. I made it in a cut:



I also made the two missing rectangular holes for the leds and power switch:


The led holes is done:


but I was not able to made the last hole. The cover slipped again from my fingers and broke again (at the same location as the first time).
I glued it again with the same method. I will finish next saturday.

Thanks for reading, next update in a few days.
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Old 9th Oct 2012, 17:52   #28
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Update of the week:
Last saturday I finally managed to finish the integration of the front apnel along with the power switch and the state leds. Here is the piece of wood, front:


and back:


In its final position with the power switch, the plexiglas leds cover and the front panel:


There is still some finishing that I will have to do after I stuck it on the flank.

I had not much time to work on my mod this week-end, beside the panel cover I only had time to test the PSU fitting and the GPU holder:




Underneath view of the PSU:


That's all until next week-end.
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Old 15th Oct 2012, 17:32   #29
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Update of the week!

This saturday I finished three points of the mod: the fixations of the PSU, the fixations of the motherboard tray and the fixations of the DVD reader.

To fix the PSU on the wood structure, I used one of the screw that hold the PSU cover (obviuously not the one voiding the warranty ):


This way the PSU is scewed from underneath:


To complete the PSU fixing, I also used two of the rear fixing holes:


The PSU is now firmly screwed on the wood, it is time to fix the motherboard tray.
It is screwed at the back on the PSU and fixed in the front on the wood (both sides of the 120mm fan).
I drilled:


And then taped the aluminium sheet:


The two screws at the front fit in a insert in the wood (they are not screwed). Here is the final result of the motherboard tray:



Last thing finished this saturday is the DVD reader fiaxtion. for this task I used an aluminium sheet and a small block of aluminium:


First step, I cut the sheet to make it fit the back of the DVD:


Second step, I cut, filed and drilled the block. I screwed it at the back of the DVD (with M2x15 screws).


I drill the sheet and then put it in position to drill the block:


Then I taped it:


And the result all back in position:


I screwed the sheet on the block and tightened it to drill the wood:


Finally I put the M4 inserts in the wood:


That's al until next week .
Thanks for reading (and forgive my spelling mistakes).
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Old 16th Oct 2012, 21:08   #30
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I like the idea of brushed aluminum, but instead of the binder idea, why not the 3M Carbon Fiber Di-Noc film? I think it would look classy with the wood

Regardless, this is a fantastic build
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Old 17th Oct 2012, 18:14   #31
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Thanks for your comment.

I thought of applying carbon fibre on the cover instead of rough brushed aluminium, but I rather stick to aluminium.
The "binder idea" is just for the GPU holder where I have to insulate the GPU from the aluminium sheet and it won't be visible.
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Old 23rd Oct 2012, 17:51   #32
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Big update for the HyperMod:

The very good news of the week is that I got sponsored by Kingston for this project.
Kingston put at my disposal a SSD HyperX 3k 240GB!!
I would like to thanks them for their support and confidence in my project.

Here si the SSD:


Unpacking it:



I received the "Upgrade kit" version, which contains:
-the SSD
-3.5" HyperX mounting bracket
-external USB SSD enclosure
-Sata cable
-HyperX screwdriver
-Acronis True Image software disc



I will try to test this SSD soon


Let's see what I did this saturday:

I drilled the bottom and the flanks to add pegs:


In order to add some strenght to the structure, I added a crossbeam at the back, also fixed with pegs:


Here is the final position for the pegs:


And the definitive structure:




I had a last operation to make to the bottom:


I made a pocket to give some room to the GPU:



The wood structure is now almost finished, I just have to glue it and paint/varnish it!


Two weeks ago I made some OCCT stress tests on the CPU to check its temperature.
In a room at 18.5C, with the stock 120mm at 700rpm, the die package did not exceed 48C.

With no fan at all (fully passive), motherboard layed horizontally:

The test failed due to too high temperature (package exceed 75C).

With no fan at all (fully passive), motherboard layed vertically:


The test passed though the CPU was very hot (cores were between 66C and 71C). But it is feasible to cool a Core I5 3450S with fully passive Hyper 612S!

Unfortunnately I need my heatsink horizontal :/.
I spent a lot of time thinking how to cool the CPU with a non visible fan, because I wanted the heatsink to look fanless. As it is the masterpiece of the mod, it has a huge importance!
I thougt about milling the Heatsink to integrate a 92mm fan but there was not enough space. Then I thought about using a slim 100mm, but it was to hard to integrate (I did not find a proper way to mill a 100mm deep pocket in the heatsink).

Finally, I made a third test with a 50mm fan layed on the top of the heatsink (after I removed the two upper fins). The fan produces about 5CFM airflow.


And it is enough to cool the CPU! But 50mm is still too big, so I will go with a 40mm fan.

In order to integrate the fan, I first had to drill a vertical hole in the heatsink:


I used a drill press and a step drill bit for this task.
Here is the result:


It is pretty clean:


Second step was to make a 40x40x10mm pocket at the top of the heatsink for the fan.
I am gonna use this ADDA fan.
I started to cut the heatsink fin by fin:


Then again it was a real brain teaser to find the better way to proceed. I tought about building a punch, using a hacksaw, using my Dremel as a milling machine...
But the easier solution is the simplest. I used a cutter!


I made a scratch on the fin with the cutter and it was then possible to tear it cleanly (fins are only 0.3mm thick).


And most of all, it was quick! Here is the final result:


The cuts are not all very clean but they are invisible from the sides:


I just miss the fan (it's in a plane between Honk-Kong and France right now) and I will be able to finish the heatsink.

Last thing I did this week-end: I finally experiment the final design of the mod, with the heatsink in position:





I definitively love it! and you?

That's all for the week

@brianwhite: yep, the mod is in good way to be finished in time !
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Old 2nd Nov 2012, 17:59   #33
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Hello folks,

I haven't updated this log since a while because I had no time to work on the mod
Good news is that I received all the cables and connectors to do the wiring. Plus the GPU is on its way to my mailbox (it's a MSI GTX560Ti TwinFrozr II).

The mod should be finished by the end of the month.

See you next week for new updates .
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Old 10th Nov 2012, 07:47   #34
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Short rsum of the work I did this week:

I started the cabling:


1st step: remove the inscriptions from the cables:

Rubbing them with acetone is the quickest way to do it

Then stripping, setting of connector and filing in housing. One done, four to go:


Five done:


And the first Sata cable is ready:


Test fit: (the cable is below the motherboard tray, it powers the SSD)


This week I received the last piece of the puzzle:


So here is the complete rig:


I was also able to test the PCIe riser with the GPU. On first boot it didn't worked
Past the POST, the screen shut down at Windows Seven start.
I had to insulate the riser with aluminium to get it work:


I now need to find a proper way to make this insulation.

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Old 12th Nov 2012, 07:30   #35
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I dig the work. Really just love the idea of the exposed heatsink, and mixed with wood makes it just perfect. Glad you got that working.

For the cable, could you just cut up a electrostatic bag (like they ship motherboards and graphics cards in) to make a sleeve and slip that around the cable? I don't know if they protect against RF, but it could be worth trying. Otherwise, they do make aluminum duct tape. You could use that and insulate with plastic vinyl adhesive sheets, or electrical tape.

I am surprised they didn't include some kind of shielding into the design.
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Old 12th Nov 2012, 11:11   #36
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Excellent project Ch2pa, lot of nice work in this.
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Old 12th Nov 2012, 18:28   #37
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Quote:
Originally Posted by G-force View Post
I dig the work. Really just love the idea of the exposed heatsink, and mixed with wood makes it just perfect. Glad you got that working.

For the cable, could you just cut up a electrostatic bag (like they ship motherboards and graphics cards in) to make a sleeve and slip that around the cable? I don't know if they protect against RF, but it could be worth trying. Otherwise, they do make aluminum duct tape. You could use that and insulate with plastic vinyl adhesive sheets, or electrical tape.

I am surprised they didn't include some kind of shielding into the design.
Thanks

I was also surprised not to have a EMC shield on the riser
I paid it about 35 because I wouldn't want to buy the cheapest you can find on ebay but I was wrong

The electrostatic bag idea worth a try
Otherwise I will try to properly stick some aluminium foil (usually used in the kitchen) with double face tape.


Quote:
Originally Posted by Waynio View Post
Excellent project Ch2pa, lot of nice work in this.
Thanks a lot

Here is the summary of what I did this week end:

First thing that I did was to finish the GPU holder:



I add some aesthetic cut and a crimped nut. The nut and sandpapering were added after the photo was taken, sorry

Then I stuck the wood structure. First, the front panel wood cover:



And secondly the whole structure:





After the gluing process and some sandpapering, here is the result for the bottom:



And the front panel: (that took me so many hours)



Another point that I finished is the CPU heatsink.

I integrated the 40mm fan directly on the second-to-last fin:





To make the fan breath, I cut the CollerMaster logo of the fin. The fan is fixed with 4 M3 screws and home-made silentblocs.

With the fan-fin assembled on the heatsink:



And with the last fin, the fan is invisible:



I just have to modify the fan cables (to integrate a resistance to undervolt it) and wire them through the heatsink.

Very soon some updates for the cables (under constructions)

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Old 12th Nov 2012, 18:33   #38
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I really like that heatsink mod. Nice work, the case looks like it's coming along nicely
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Old 12th Nov 2012, 18:36   #39
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Thanks

And the best part is that it actually works and is enough cool efficient for the i5 3450s!
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Old 14th Nov 2012, 17:13   #40
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Keep it up looking forward to seeing this finished.
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