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Old 9th Mar 2017, 02:16   #1
Cleveland216
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Proxima C: Update: 4.24.17

Hi! It's been a long moment since I've built a case and had a project log. Where have I been and what I have I been doing? To those of you that don't know me who am I?

My modding "career" started a long time ago in the year 2000. Back than I didn't have a camera so my early cases, which, were mere tower mods with windows and autobody paint body and some lights. It wasn't until 2007 and my Triphane build that I started to show my ability. I hit my stride in 2009/10 with my first scratch build Aelro Dynamic, all aluminium, which, was folllowed by SSR-X, all carbon fiber build.

After SSR-X, I founded and tried to jumpstart a wearable technology company, which, failed! It was one hell of a learning experience! SSR-X was created with Google Sketchup, but my wearable technology demanded that I learn SolidWorks. Gained some really valuable knowledge in the art of design and assembly. Pictures below!



I'm sitting around and the Cooler Master World Series competition pops up on the radar. I'm eyeballs deep in projects already but in the past 6 months I was designing case in my spare time. With the competition and my aging hardware, I finally decided it was time for a new case, Proxima C.

Proxima C will be my first fully acrylic case. It somewhat of tribute case to the discovery of Promixa B in the Alpha Centauri System, within, the last year! I wanted to make a case that didn't look of this world.



Material is on order! As always Until Than, Keep Modding

Last edited by Cleveland216; Yesterday at 12:24. Reason: update
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Old 16th Mar 2017, 23:23   #2
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Update: Hardware

Update:

Proxima C is going to be a water-cooled case. This past weekend after a basic completion of the design and ordering of the Acrylic, I went ahead and ordered the watercooling parts.



Thermal Take Ring Fans. They look awesome when lit!



Slim Triple 360mm Radiator. I don't for see an SLI setup so these 2 should just do.



Promixa C can hold up to 4 Reservoirs, though, 2 will only be attached at first.


Laser Cutting this weekend! Until next time!
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Old 18th Mar 2017, 13:12   #3
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Update:

Update:

Have you ever seen 4 x 8" Sheets of Cast Cell Acrylic? Proxima bill for material requirement is quite large. While I haven't calculated the exact square footage of material it will approximately take upwards of ~60% of these 2 - 4 x 8" sheets of acrylic.



The Colors.



Next up Cutting and Laser Cutting! Until next time.
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Old 19th Mar 2017, 01:58   #4
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Update

Update: Cutting Acrylic

Before I started to cut the acrylic, I wanted to make sure that all the parts were correctly to size. I created Drawing files in Solidworks and I went to my local print store to get them printed off.

With printing off Blueprints, I also wanted to save material as much as I could. I originally sourced acrylic material to Delvies plastic. I ran into a problem, in that, I would waste to much material over the build, due to their standardize sizes, and that would cost me $200 more in build cost. Buying 4 x 8' sheets lets me cut out just what I need and efficiently lay out all the parts so that I can save money.



My printed off blueprints. 36" x 8'.

These will just give me the dimensions for each piece I want to cut and fit in the laser cutter. New DXF files will be created for actually importing into the laser cutter and cutting out the parts.



Another view of the entire blueprint. This just encompasses the Radiator Assembly of the build



Size and dimensions of each sheet of acrylic.



I usually cut material with a fiber disc because it is usually metal. It is nice to be able to use a Jig Saw and not create such a big mess and have material fly in my face!



Cutting.



More parts that create the Radiator assembly.

Laser cutting tomorrow, if it all goes well! Until next time!
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Old 21st Mar 2017, 00:15   #5
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Update: Laser

Update:

In Cleveland, Ohio, where I live there is a place called ThinkBox that lets the local community come in and use various equipment. Until recently, it was in a small space in the basement at a local university. ThinkBox got moved into a new 50,000 sq ft remodeled building on its campus. Plus they got a bunch of new equipment.

I was suppose to start laser cutting yesterday, but they were closed due to spring break holiday. Thankfully they be open all week and weekend. I have a large amount of Acrylic to cut!





They have 2- Universal 75/150 watt laser cutting machines When I saw these, I knew this was going to be awesome!



A former student was etching a project, so I decided to roam the room and see what else they had to offer and came upon this ---->>>





Free Hardware!! I found heaven, lol!



Took my Solidworks Drawing file, converted into DXF and imported into CorelDraw and shot it over to the laser cutter.





I need to establish just how long it would take to cut out my designs. I was getting some horrible run time numbers but luckily the data that was being provided was wrong.



The first sheet was turning out ok. The power setting were set a little low.





The settings were corrected and the second set of parts turned out great! Perfect cut through! I was in the lab for about a total of 2 hours plus there was some wait time.

I like to say the cut finish is really nice! Until next time
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Old 23rd Mar 2017, 11:06   #6
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Update:

Update:

This whole week has been to the dedication to get as many pieces cut for Proxima as possible.

Proxima is built in 3 separate distinct sections. I started by working at the bottom, which is the radiator assembly portion of the case and working my way up.



Setting the Laser to Cast and dialing in the power settings.



This is one of the Radiator Side Frame pieces for the assembly that is being cut. The first piece in this laser cut run did not go well, because the machine was off calibration.





These pieces so far are coming out well, but they do have some minor flaws because of cutting from a laser, which, will be pointed out in a later update.



Finished piece.





I have to turn the power setting up nearly all the way so the laser cleanly cuts through the acrylic.



My largest sheet of cutting. 24 x 48".



This piece was used to cut out the power supply section of the case. This piece which is being cut here represents a frame piece in that portion of the case.



This frame piece is the support bracket for the power supply. I actually have to go back and modify it because my design is a bit off.

That is all for now. Until next time
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Old 25th Mar 2017, 13:17   #7
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Update

Update:

Its been a busy week at ThinkBox getting all the pieces laser cut.

I will be assembling the Radiator assembly portion of the case this weekend but before we get there, I had to finish cutting out some pieces for that section.



The radiator mounting frames and the Radiator to Mid-Section Joiner piece.





The pieces laser cut! I'm actually had to go back and re-cut all these pieces because the tolerances were off. The laser takes a 1 mm off on cut, so when designing to tolerance, I was actually over tolerance because I didn't think of the width of the laser beam.



Got started on the Upper Frame section of the case, which, will house the motherboard and video cards.





Sneak peek.



These are side frame pieces for the mid-section where the power supply will be house. They also help support that section.





Opps! These piece flopped out after cutting! It could have broke the machine Thankfully I didn't have to stop the machine. These are some pieces that had to be re-cut because the tolerance was off.

That is all for now. Until next time
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Old 27th Mar 2017, 12:24   #8
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Update:

Long Weekend!

Where to start....to start to assemble the radiator section and it subsequent power supply assembly above it, I had to finish laser cutting some pieces. The weekend was dedicated to trying to get the radiator assembly assembled. It would also let me know what type of build time I'm in for and the complexity of the build finally.



Side frames for the power supply assembly section. There purpose is to support and to provide interlocking transition to the radiator assembly.



When the laser cutting setting are properly dialed in, the pieces after cutting fall right out. With 5mm cast acrylic I had to turn the power setting up to nearly 100% to get a clean cut.



The long skinny piece is for interlocking the radiator frames. They had to be re-cut because of over-tolerance issues. I cut extra pieces because it would help in holding the frames while they were glued.

Radiator Section Assembly



Searched for Weld On 3 online, which, I found is now this product. Good thing is that I was able to order this locally through McMaster Carr in my area. I also order syringes and 14 gauge needles.
My previous experience using acrylic glue years ago was somewhat a nightmare because I wasn't using needles like I should have been.



These are radiator side frame brackets. They are all wrong!! For some reason the holes are off by about a millimeter. Luckily they are small in size and I have ample material so they will all be re-cut.



Interlocking Radiator Frame supports.



Radiator brackets. First time in all my build I get to make standardized radiator back support bracket.



Main radiator frames. I do love the shiny edge that laser cutting leaves on acrylic. No need to polish!!



Before I start assembling the frames they need taped out to hold their side frame brackets. 10-32 tap.



Carefully peeled away the area in which the bonding is take place. I want to keep from getting acrylic all dirty or damaged.





The radiator frames pieces in alignment and the interlocking piece in place ready for bonding.



The interlocking piece and its position from another angle.



Next up is the Radiator bracket. This is also bonded to the Radiator frames to give the assembly added rigidity and support.



Test fit. It looks good!



Add some 120mm fans.



The radiators and fans finally mounted to the bracket.



Got both radiators mounted to their brackets. The assembly is far from being done though. There are still 2 radiator frame pieces missing due to miss cutting. The outer radiator side frames are still not mounted and that is what will be worked on at the beginning of this week.

Until next time.
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Old 28th Mar 2017, 12:30   #9
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Update

Update:



Went to think ThinkBox on Sunday and cut out the 2 Radiator frames that didn't laser cut right the first go around. I also had some side brackets for the power supply assembly that needed cut.





To mate the Radiator Assembly to the Power Supply Assembly I created this bracket. I really had to stare at the case for a long time in Solidworks to get a feel for the design I wanted.



Finished off bonding the 2 radiator frames to the rest of the completed assembly at my house.



Started to mock up and test fit the pieces for the power supply section of the case.

Until next time

Last edited by Cleveland216; 28th Mar 2017 at 12:37.
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Old 30th Mar 2017, 12:17   #10
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Update:

Update:

Off to ThinkBox to laser cut the Main Frame pieces for the motherboard tray. Little did I realize that when I got home and compared them against the first 2 that I would find out the first 2 I cut were somehow off (oversized). Never fails!



Oriented and ready to cut.



Focus the laser and were off.





Skip ahead and shazma, there done!



Turned out pretty nice for the most part. There assembly will in a couple weeks or less.



Finally got started on Side Frame pieces for the Radiator assembly.



Started by bonding the frames from the bottom working my way to the top.

Interesting point here, is that in casting the acrylic, the thickness slightly changed throughout sheet. Even though everything is cut to the correct tolerance, I found some pieces were tighter or looser than they should have been. So I had to fit appropriately.



Basically completed. I just have to wait for full cure and I can turn the case around and do the front side.

Until next time
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Old 4th Apr 2017, 12:08   #11
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Update

Update:

I've been working away meaning to an update for the past 4 days.



I turned my attention to finally start lasering the Upper Main Frame pieces. This section of the case is where the motherboard and video card will be mounted.





There are 5 of these Frame pieces.



I mounted the Power Supply onto its plate and found that is was causing the acrylic to bend. So I went ahead and re-designed its mounting plate for added support and it is what is being cut here.



My file was completely right and I was missing a cut out on the lower side in this picture. After some careful layout placement I was able to cut out what was missing.



With the new piece cut, it was time to mount the power supply. I was going to radically mod out the power supply but I took a step back and looked at it and found it quite appealing in its current configuration.



Back to ThinkBox to finally finishing off the cutting for the Upper Main Frame section. I ran out of Black Cast Cell and I had to order another sheet of 4 x 8'.



These pieces will Wrap the other Main Frame pieces that were shown above.



Current state of the build this past weekend.



To mount the Reservoir, I designed in Solidworks these blocks. I thought about making them out of metal but material theme of the case is acrylic! This case will be about to hold 4 Reservoirs, though, I doubt it will ever truly see 4.



Mock up and time to drill and tap.



Drilled the holes for the Res and placed the mounting block and marked for some holes.



Had to add these washer, because the spacing distance between layers is 20mm. For the outer brackets to fit correctly, I need the spacing distance to correct.



Outer Brackets bonded into place. These brackets holds the frames together and is the support for anything mounted above it.



A view of the Res mounting block. What also can be seen here is that I need a 90 degree power supply cable!



Current state of the build with one Reservoir mounted.

Until next time
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Old 9th Apr 2017, 12:43   #12
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Update

Weekend Update.

I've been working away on 3 projects so my time has been limited on work log update. The work hasn't slowed down on Proxima and I'm nearing the end of construction.

I'm also going to updating the work log with design renders from Solidworks.



Got the motherboard plate cut out. Drilled the holes for the brass supports and marked off where the main frames are suppose to be bonded into place.



This was a tricky task of bonding. I should have created a jig. The whole Main Upper Frame will be supported and bonded by many pieces holding it together.



My spacing tool.



Got 4 frames bonded in place. The next step is to bond and mount the Side Frame pieces.
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Old 9th Apr 2017, 13:03   #13
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Update: Solidworks

Solidworks Design Renders



The Radiator Assembly



A head-on view.



Middle Frame Assembly. The mock-up on the power supply. I wish the modding community had a more vast library of CAD files online.



A head-on view.

I think one of the really cool aspects of this case that makes it unique is that when you change what angle you're looking at the case the look and feel of the case changes.

I like to think of this design as a free-flow design. In trying to blend complex with simplicity while also trying to achieve good performance from the parts in the case.

I use to bury my radiators in my case and try to direct the airflow. This case is a big departure for me because now the radiators while buried are very open to air-flow. It will be interesting to see what type of lighting effect the case gives off when finally powered up.

Until next time Thoughts??
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Old 12th Apr 2017, 12:00   #14
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Update

Trying to get the case done in the next week and half so I can get professional photos taken of it.



Ran into a problem! The Upper Main Frame where the motherboard sits causes the Middle Frame Section to sag and bend. I had to go create these extra bracket support pieces. The design looks good in Solidworks, but in real life, not as planned.



Placement of the bracket pieces.



With the Upper Main Frame sitting stable, I was able to finally go ahead and start mounting the Outer Frame Side pieces. These provide additional support to rigidity and stablility. It also gives a certain aesthetic look to the case.



I had to take into consideration about installing and un-installing part if I need to.



Originally the front of these were straight but I re-designed and put a triangle design onto the front for a better look.

Until next time.
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Old 13th Apr 2017, 11:58   #15
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Update

Got to work last night bonding the brackets for the Upper Main Frame assembly.





I was originally going to re-design these so that a bolt would hold the Upper Main assembly into place with this bracket. I ultimately decided that the Upper Main assembly would sit into place in the bracket without any bonding or fastening. The fit is pretty tight into the slots.



Bonded the first one and used these spare pieces from the pump support bracket to help me properly align and bond the other bracket.





The Upper Main assembly somewhat fitted into place. Only 2 of the main frames are used in the bracket. The other 3 float in the air and are supported together by all the other pieces.

Until next time
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Old 17th Apr 2017, 12:14   #16
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Update

Hello! Closing in on the final week of building before the May 3rd deadline. On the list that still has to be done is sleeve the power supply, finish mounting some hardware, run the rigid tubing, finish bonding the Upper Side Frame pieces, photography, and assembly.

Went to Microcenter over the weekend and picked out my motherboard. With the results of AMD Ryzen and its cost, to me it was the only logical way to go with my next system.



I've always had Asus products in my build. IMHO, there great products that hold up over time and I've had every little issues with.



Second pic with my GTX 480 video card. Old technology. I just don't have $500-1000 to drop right now on something top of the line. I had an SLI setup in SSR-X so I just pulled the second card for this build.



I spent the good part of last night peeling off all the acrylic protection covering for the middle frame assembly. I need to bond into place these support brackets, so I figured what the heck lets get this over with now. Busy week ahead, so I took an extra moment to save some time in the long run.



I also bought some Air Blaster cans. There is dust and stuff all over the case.

You can start to get a glimpse of what the case will look like when the wrapping is all taken off. The black acrylic is actually transparent while the Red is more translucent.

I did that because I wanted the light to shine through the black and reflect off the red. It exposes depth and shadow while still attracting your eye to the edges and providing solid barriers for confinement.



Bonded the top of the Main Side frame pieces into place. I actually flipped the whole assembly upside down. I'll be working on these side frame pieces today. Which is the last of the major components to be built out.

Busy week ahead! Until next time
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Old 20th Apr 2017, 12:07   #17
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Update

I found trying to mount and bond together the Upper Frame Side pieces to be quite tricky. So I tried something new in trying to bond it together.



Instead of having the pieces mounted on the case on than bonding it together, I marked the location where the support brackets are to be bond to the side pieces and than bonded.



Side view of the construction. I also used various pieces of material to help with proper placement and tolerance.





All 4 pieces bonded into place on the bracket.

Problem



After mounting the assembly into place, I saw that the side frame pieces were not straight! In theory, it looked like it would work in Solidworks for mounting, it was the weight of the frames that were sticking out that was causing the issues along with inadequate mounting.



Went back and added in another mounting bracket in the middle and check all my bonded connections.



Another pic of the problem.



It came down to scrapping the whole assembly or creating a secondary mounting bracket. I thought long and hard about both. I thought about a hanging bracket, inside bracket, outside bracket, though, I wanted a bracket that would flow with the case. Something minimal too. This is what I created.



Nice and straight like I want it.



Next up is mounting the motherboard and the side frame pieces next to it. Than onto Tubing and power supply sleeving.

Until next time.
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Old Yesterday, 12:22   #18
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Update

Closing in on the end of assembling the case.

This past weekend I spent much of my time, sleeving the power supply and looking over installing the tubing.



Bought these bad boys from Performance PCS. I decided to go with rigid tubing for the first time in all my case builds.



To contrast nicely with the overall look of the case. The colors will also let me follow water flow. Red being Hot and Blue being Cold.



Installed on the radiator.



Got the pump sleeved and installed the fittings. I'm going to look around for other connector tops to replace those generic black ones.



Measuring out the cables and figuring out there routes.





I used tape as marker for where to cut the lines.

All for the moment. Until next time.
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