Scratch Build Lean and Green - 20-Dec-12 - preview of next project & status update

[Fifas]

This is like...Aluminium porn

Awesome work man!

[Mosquito]

Man that looks sweet

[riekmaharg2]

Awesome scroll saw skills, bet it was nerve-racking to cut out thoughs crazy thin sections in the center of the fan grill.

Also JB weld won't stick very well to anodized pieces unless you sand off the anodizing where you want to stick it.

[quizz_kid]

Wow Waynio, it looks amazing. Cannot believe how good that one looks! Hard to get those fine cuts that perfect... Who needs a laser cutter when you´ve got a Waynio

[jokkos]

...........

those cuts on the fan cover...
very, very impressive. So precise, it all looks so good together!

[Cleveland216]

Hey! Been away for a moment. The progress on this case is Amazing. The work is Astounding! Once again imho a real MOTY contender here.

[Squigly]

+1 on this being pron!!! I must say I am almost sad that it is starting to wrap up This is where i come for my modpron fix!!

Its looking really good Waynio, your patience and craftsmanship shows through in every update bud!!

[Waynio]

Originally Posted by Sarakon

That looks really awesome loving it...and the speed of updates has increased 10 fold

Thanks Sarakon appreciated

Originally Posted by KoSoVaR^

You are sick man!
That looks soooo awsome

Thanks KoSoVaR

Originally Posted by Fifas

This is like...Aluminium porn

Awesome work man!

Thanks Fifas

Originally Posted by Mosquito

Man that looks sweet

Thanks Mosquito

Originally Posted by riekmaharg2

Awesome scroll saw skills, bet it was nerve-racking to cut out thoughs crazy thin sections in the center of the fan grill.

Also JB weld won't stick very well to anodized pieces unless you sand off the anodizing where you want to stick it.

Thanks Keir, yeah I start from the centre going outwards so the last piece is a bit tricky doing the u turn cut lol, the thin line closest to the outside is most nerve wrecking on these with the thought of if the blade welds to the aluminium it would mangle it good lol.
Thanks for the heads up on the JB weld too mate, appreciated.

Originally Posted by quizz_kid

Wow Waynio, it looks amazing. Cannot believe how good that one looks! Hard to get those fine cuts that perfect... Who needs a laser cutter when you´ve got a Waynio

Thank you quizz, appreciated mate.
One tiny hicup about the HTPC fan is I slimmed the perch to 19mm back when I thought I could do the fans in same depth as stock 25mm but I needed the extra 1mm so I'll have to make a 1mm panel to fill the missing bit again so the fan fits nice & tight.

Originally Posted by jokkos

...........

those cuts on the fan cover...
very, very impressive. So precise, it all looks so good together!

Thanks jokkos, hoping to be moving up to the gamer rig after the next session.

Originally Posted by Cleveland216

Hey! Been away for a moment. The progress on this case is Amazing. The work is Astounding! Once again imho a real MOTY contender here.

Good to see you Dave the big test is can I complete this in time lol, trying not to sweat about it.
It's a contender but the looks are very much an acquired taste, had plenty express how they don't like it so this will place low if I make it in time but I don't care, whatever happens I'll be smiling about the fact I completed it in time & see my craziest creation so far as a usable rig.

Originally Posted by Squigly

+1 on this being pron!!! I must say I am almost sad that it is starting to wrap up This is where i come for my modpron fix!!

Its looking really good Waynio, your patience and craftsmanship shows through in every update bud!!

Still a lot to do Squigly I'm just dedicating more so it can be wrapped up sooner rather than letting it go into a 2 year project, I'll be doing more next year I'm sure but nothing as OTT as this or at least think I won't (I thought this with stealthlow) lol.
Thanks mate.

Went to do a session but figured I should design the spindicator electronics case, it's not quite a simple box but it will help to clean up the mass of wires to do with it & will prevent it from having an accidental short & it only just fits into the space by the PSU.






I'll make a start on it along with getting the rods installed, 10mm plates rounded, HDD covers installed, fan completed & get the stand cover installed so I'll be modding all night with an update or 2 tomorrow some time.

[Waynio]

OK I was a little bit too ambitious about what I said I'll do on my previous update but I made some progress.

Got a start on the spindicator electronics casing 3 5mm acrylic sheets.


Stuck together.


Both aluminium covers.


Then made a start on the fan by filing the rods.


1 of them went nicely because I took care doing it, the others I got careless, they work nicely but don't cling to the hoop because of taking too much off so with this one being on full show I'll likely make new ones & use these ones for fans that aren't on full show.


Making the hoop, used whatever I could to get a basic hoop, the strip was too long so had to grind ?mm off bit by bit until...


It finally clicked in place.


Then you align the 2mm panel & work the hoop into it until it sits flush.


Then you put your fan in there or as I done mount the front 1mm panel.


I bent the 2nd set of HDD covers, they are good but making them join to the rod & look good how I designed it is really difficult to do, I tried using the mill bit to flatten a length of the bar so the cover would sit flush but I screwed up, I'll work out a way, an idea has already formed while writing this out & it's a good one but does require a 3rd fabrication of the covers.






But yeah, I couldn't resist chopping up 1 of the aluminium fans to put it in there lol, snipped all the LEDs off it & cut the outer frame off & the fan & 4 plastic legs slid in perfectly.














So I got 1 bit done & 2 other bits semi done, really can't wait to complete the HTPC so I can move over to the gaming rig.

Loving the custom fans, you have to wrestle the hoops into place but when they click in it's just an awesome satisfying moment.

[Attila]

Wow Wayne. I'm almost speechless! That's extraordinary. Stunning, Intricate, Original and just awesome!

[alain-s]

The fan housing is really beautiful it gives a nice thought to the aluminium Prolimatech fan. Looking forward to the completion of the HTPC so U can start on the next part.

[jinq-sea]

Heavens. That's quite incredible!

[Mosquito]

I think the Aluminum fan makes that really happen. It looks so good, but then to not break up the look by having a black plastic fan in it is a huge detail that makes it look even better.

I refuse to believe that you don't secretly have a CNC or laser...

[Sarakon]

So you had the urge to install the fan. Did you also power it up?

[Squigly]

wow... that fan is a thing of beauty!! closing it off like that just gives it the perfect finish!!

[quizz_kid]

Well, I´ll just

[Waynio]

Originally Posted by Attila

Wow Wayne. I'm almost speechless! That's extraordinary. Stunning, Intricate, Original and just awesome!

Thanks Attila, appreciated.

Originally Posted by alain-s

The fan housing is really beautiful it gives a nice thought to the aluminium Prolimatech fan. Looking forward to the completion of the HTPC so U can start on the next part.

Thanks Alain, I wasn't sure if the hoop would fit so nicely but the only part where it dips out a touch is at the join, the rest looks & feels seamless, I'm even going to leave the prolimatech minimal sticker on because they released an awesome fan & these wouldn't have looked so good without them, glad Asouter nudged me into going for a couple of them despite the price.

Originally Posted by jinq-sea

Heavens. That's quite incredible!

Thank you jinq-sea

Originally Posted by Mosquito

I think the Aluminum fan makes that really happen. It looks so good, but then to not break up the look by having a black plastic fan in it is a huge detail that makes it look even better.

I refuse to believe that you don't secretly have a CNC or laser...

It does, awesome for catching light reflections, enermax inspired me on making aluminium fan frames because the plastic they use on the moddable ones I used on stealthlow was really weak & brittle & the hoop thing got me thinking but wanted to do the hoop in 1 piece instead of 2.

I really do think a scroll saw is a good alternative to laser & could even use a slim dremel cut disc for a start hole if doing very thin lines in a design but it couldn't do engraving unless using layers.

Originally Posted by Sarakon

So you had the urge to install the fan. Did you also power it up?

Not until it's properly fixed in there, it's just loose fit at the moment.

Originally Posted by Squigly

wow... that fan is a thing of beauty!! closing it off like that just gives it the perfect finish!!

Thanks Squigly, getting the hoop in there is pretty difficult though but quite awesome when it snaps in place, was a little worried I'd have to do it in 2 half's but persisted.

Originally Posted by quizz_kid

Well, I´ll just

Thanks quizz.

Well it's mod on time now & tweaked the design a bit for the 3rd attempt of the HDD covers, hopefully will get a good bit done tonight.

[Nutman]

Hm.... interesting.

Did Waynio just surpass Attila there?

Anyway... trying to keep count on how many times I've given rep to Waynio in this thread (or tried to), but I gave up counting and tried again. I failed. Gotta spread love to other builders first. Damn.

[C4B12]

Waynio you are one sick dude!

[Waynio]

Originally Posted by Nutman

Hm.... interesting.

Did Waynio just surpass Attila there?

Anyway... trying to keep count on how many times I've given rep to Waynio in this thread (or tried to), but I gave up counting and tried again. I failed. Gotta spread love to other builders first. Damn.

Blasphemy
Thanks Mads

Originally Posted by C4B12

Waynio you are one sick dude!

Thanks C4B12

I made today an easier day because I was starting to get worn out lol.

Resumed the spindicator electronics casing by first flattening the edges of the acrylic stack & then some drill milling but I took my time doing it to not strain the press.






After that I countersunk all the mounting holes & then plugged brass inserts with the soldering iron into the middle of the 15mm stack so it could be shared by 2 8mm countersunk screws on both sides.


Then cut the internal piece out. using the copper cooling trick on the blade.


Acrylic piece done.


Then had to countersink a tiny bit more to make them nicely flush fitting screws on the 1mm outer panels, turned out nice.




The electronics this case is for.


I used vinyl on the underside for the electronics in the hope that will be good enough to prevent short circuit, if it isn't though I can paint the solder points with liquid electrical tape or put a layer of electrical tape down.


The Molex plug slots in place really nice, I intentionally left some space around the PCB.


Top cover on & this little case is done.






For the rest of the wires going from this to the spindicator I will make a quick channel case from acrylic & aluminium scraps that keeps all the wires safe from snags & cleans the looks up even though it will only ever be seen during building up but will be nice to know there isn't chance of wire snags.


I might get this HTPC completed some time lol.