Project: HedgeBox (passive HTPC) Easter update - bit-tech.net Forums

Tursas · 13th Mar 2007, 02:54

Hello All!

This is my first post and my first mod. I started this project earlier but now finally get to log it.

I have been in need of HTPC for a long time. I mainly watch divx and play mp3s.I just hate to have my noise and energyconsuming desktop computer on just to play a episode of southpark. I looked at the market but did not find something what would look interesting (I did like Mcubed's HFX case with passive cooling).
So if you can't buy it, build it!

I set few criterias for the build:
1. Quiet
2. Low energy consumption
3. Looks good
4. Can take a bullet (I hate flimsy products)
5. Looks different

I bought few months ago a joblot of big heatsinks. I been thinking what to do with them until I got an idea of just bolting them together to form a case.

Size is 120mm x 120mm x 45mm and each weigh 780g.

After brainstorming I formed up the case in Sketchup.

Don't know what to call it. Xbox is taken....hmm I like hedgehogs....hmm... So let's just call it Hedgebox (If anyone has better suggestions let me know). The case in made out of 13 heatsinks. Wooden bits will be probably rosewood or some nice darker wood.

From inside it would look like this

Because the the case is basically one big massive heatsink there is no need for fans. With heatpipes I will transfer the heat from the components.

Speaking of componets.
Mobo: Aopen i915Gmm-HFS
CPU: Pentium M 1.83 (or whatever it was)
PSU: PW-200-M with external 150W brick
Cooling: Mcubed Borg CPU, GPU and northbridge heatpipe coolers
LCD: Matrix Orbital 204 series
remote: Soundgraph iMON 2.4G DT PCI
Optical: Any good slim slot drive
HDD: Any good 3.5"

So let's get cracking!

zachjowi · 13th Mar 2007, 03:09

looks cool. good luck. I might have atleast 1 quiet 120mm fan

Tursas · 13th Mar 2007, 03:25

I have been doing some measuring and testing. Trying bit's different ways.
Think three times, measure twice,cut once. I tend to haste with things

Piling up the pieces with cardboard template.

First thing is to cut the small pieces from the sides to fit the sidesupport later. This is the most annoying and tiresome stage. I still have not done all of them. Note the truly DIY cutting table/vice made out of gaffer tape and a vacuum cleaner to suck of deadly aluminium powder.

I was thinking a long time how to bolt the heatsinks together until I came to this solution

I will drill trough the heatsink and put a long rod trough them and then tighten the whole thing. Also the rod might transfer some heat (or not).

I bought a new bench drill for this project (£100, a bargain). Biggest problem was to align two opposite holes (drill bits were too short to drill trough). Patience and measuring gave me good results. When drilling thick aluminium I found best to have high RPM and keep the drill bit lubed with WD-40. This will
will eject chipping nicely and keeps the bit cool.

After spraying my house aluminium chipping I have made one wing ready.

Making the threads to 1/4" copper rod with die

Tapping the holes for the threaded rod.

Joining nicely.

Ah, beautiful! three more to go....

jakenbake · 13th Mar 2007, 03:56

wow, nice craftsmanship. good luck, looks sweet.

dacust · 13th Mar 2007, 04:55

I REALLY like teaming up those heatsinks with a nice exotic wood. That will make the difference between a metal monster and a rich looking machine.

Can't wait to see the final product!

cyberspyder · 13th Mar 2007, 05:33

The aopen NB heatsink looks like some sort of word...

DAE_JA_VOO · 13th Mar 2007, 06:05

This is cool, but there's a problem.

I dont wanna rain on anyone's parade, but lemme just explain something. The component that the heatpipe is COOLING must be LOWER than the heatsink, otherwise the entire concept of a heatpipe is void. Just like you can't put a mobo that has heatpipes upside down...

Jipa · 13th Mar 2007, 08:20

It depends on the heatpipes he's using. The ones with nothing else but water in them won't work, but there's also those that do. I don't know how they do it, but they definitely do.

The problem I can see here is that unfortunately the CPU and the GPU aren't the only parts that heat up. I'd have one 120 mm fan in the middle of the back panel (none will even see it?) at very low speed so it would be inaudible. or atleast have some holes for the warm/hot air to escape from the case! Most of all I'm worried about the lifespan of the capacitor if it gets hot in there..

Nice and unique design anyways!

ottzen · 13th Mar 2007, 08:52

Why wouldn't heatsinks work if the mobo is upside down? O_o
Not that I have any proof, but by the laws of physics any copper, aluminum, or steel rods will lead heat much better than the surrounding air, so there will definately be heat lead through there!
Thing is though, that you'll get extreme hotspots with the mobo upside down, because hot air wants to rise and its so much harder to go anywhere if there's a mobo in the way

Imo you should DEFINATELY put in som kind of fan.
If you turn the mobo around you should also be fine with ventilation holes, but there's nothing like a low speed 120mm fan.

But nice work with the drilling and sweet heatsinks you got there.

//ottzen

Jipa · 13th Mar 2007, 09:36

HeatPIPES, not SINKS

TMM · 13th Mar 2007, 10:06

Some heatpipes have wicks (sp?) in them which allows the liquid to still travel due to capillary action afaik.

Tursas · 13th Mar 2007, 11:12

Thanks for the reply's guys.

When I decided to go passive I knew I would run into load of problems. But because projects must be challeging I will keep it totally passive with no fans in it. The mobo and cpu produce very little heat, so I might get lucky.

Heatpipes are made by Mcubed so they are the one with wick in it. So they will work in any angle.

I will not have case totally enclosed. There will be some holes. Where and how big is up to the wood what im gonna use. Here is some layout I made this morning

In a perfect world the cold air will come from the bottom grills and escape from top grills. I think I would make holes more narrow....

What comes to position of the motherboard. Its the case of "Form before Function". I could have it lying on the bottom with face up. But because I want to have DVD drive under the LCD display and this is the only way it fits. Again this is a situation what might change when I have computer up and running. Front piece is the last thing I will do.

Burnout21 · 13th Mar 2007, 13:58

dude this HTPC will weigh like 20Kg!! at leat no one can run off with it quickly!!

guysy1110 · 13th Mar 2007, 14:07

This is a sweet idea. I think you will be able to keep it passive if theres no marjor gaming, apps running all the time... i would love to have something quiet when im watching a film lol.

Good work.. keep it up

Bas van der Werff · 13th Mar 2007, 15:34

Sweet idea

where did you get those heatsinks?

dacust · 13th Mar 2007, 17:17

Quote:

Originally Posted by Tursas

I will not have case totally enclosed. There will be some holes. Where and how big is up to the wood what im gonna use.

I'm sure whatever you come up will look good, but to me the earlier drawing with nothing but wood and heatsinks showing has a really nice look. IMO it'd be nice to not have any grills cut in the wood that show. Maybe have inlet grills cut in the wood on the underside, but the outlet grills in the back at the top?

EDIT: OK, I didn't look back at the photos myself. The back is covered with heatsinks, duh. Still it'd be nice to find some way to keep the grills from showing. Maybe cut out slots in between the fins on the back?

Tile · 13th Mar 2007, 17:36

Deleted

ottzen · 13th Mar 2007, 18:33

Quote:

Originally Posted by Jipa

HeatPIPES, not SINKS

My bad...still meant and talked about heatpipes though. Can't see a reason why they wouldn't work upside down...

Totally agree, that projects should be a challenge, so keep up the passive idea! Just don't forget ventilation holes

€dit:
One other thing though.. how did you plan to work out the I/O-shield? Make an own, or is the mobo just turned the wrong way in your sketches?
I'm guessing you won't cut holes in the heatshrinks, so this should be intresting

//ottzen

rowin4kicks · 13th Mar 2007, 18:48

wow i love the wood and heatsink mix! very origional!
i love the design idea as well, but maybe having a low under volted 120mm fan at the back blowing in air which can escape throught the vents at the top would just improve the lifespan of the computer
or maybe a fan you can turn on when it gets too hot inside
anyways good luck and its you decision!

Jipa · 13th Mar 2007, 19:22

Quote:

Originally Posted by ottzen

My bad...still meant and talked about heatpipes though. Can't see a reason why they wouldn't work upside down...

//ottzen

The problem is that the water in the pipes tends to go down because of gravity. If the part that needs cooling is located to the top of the pipe, that doesn't work too well.

There's also heatpipes with some sort of mesh inside so there's capilar effect or something. Those work in any position.

13th Mar 2007, 02:54	#1
Tursas What's a Dremel? Join Date: Feb 2007 Location: London <-> Helsinki Posts: 9	Project: HedgeBox (passive HTPC) Easter update Hello All! This is my first post and my first mod. I started this project earlier but now finally get to log it. I have been in need of HTPC for a long time. I mainly watch divx and play mp3s.I just hate to have my noise and energyconsuming desktop computer on just to play a episode of southpark. I looked at the market but did not find something what would look interesting (I did like Mcubed's HFX case with passive cooling). So if you can't buy it, build it! I set few criterias for the build: 1. Quiet 2. Low energy consumption 3. Looks good 4. Can take a bullet (I hate flimsy products) 5. Looks different I bought few months ago a joblot of big heatsinks. I been thinking what to do with them until I got an idea of just bolting them together to form a case. Size is 120mm x 120mm x 45mm and each weigh 780g. After brainstorming I formed up the case in Sketchup. Don't know what to call it. Xbox is taken....hmm I like hedgehogs....hmm... So let's just call it Hedgebox (If anyone has better suggestions let me know). The case in made out of 13 heatsinks. Wooden bits will be probably rosewood or some nice darker wood. From inside it would look like this Because the the case is basically one big massive heatsink there is no need for fans. With heatpipes I will transfer the heat from the components. Speaking of componets. Mobo: Aopen i915Gmm-HFS CPU: Pentium M 1.83 (or whatever it was) PSU: PW-200-M with external 150W brick Cooling: Mcubed Borg CPU, GPU and northbridge heatpipe coolers LCD: Matrix Orbital 204 series remote: Soundgraph iMON 2.4G DT PCI Optical: Any good slim slot drive HDD: Any good 3.5" So let's get cracking! Last edited by Tursas; 6th Apr 2007 at 18:59.

13th Mar 2007, 03:56	#4
jakenbake full duplex Join Date: Jun 2005 Location: Ohio, USA Posts: 494	wow, nice craftsmanship. good luck, looks sweet. __________________ 1 + 1 = 10

13th Mar 2007, 04:55	#5
dacust What's a Dremel? Join Date: Mar 2007 Location: Georgia, USA Posts: 409	I REALLY like teaming up those heatsinks with a nice exotic wood. That will make the difference between a metal monster and a rich looking machine. Can't wait to see the final product! __________________ -dan My programs don't have bugs, they just develop random features. WaterPlant worklog - in progress - Bit-Tech article - WaterPlant site - Home Page - PowerPlant PC - Designing Don't worry about your english. This is an international forum. That's what makes it great. If I don't understand, I'll ask. Just MOD ON!

13th Mar 2007, 06:05	#7
DAE_JA_VOO Supermodder Join Date: Nov 2005 Location: Pretoria, South Africa Posts: 313	This is cool, but there's a problem. I dont wanna rain on anyone's parade, but lemme just explain something. The component that the heatpipe is COOLING must be LOWER than the heatsink, otherwise the entire concept of a heatpipe is void. Just like you can't put a mobo that has heatpipes upside down... __________________ Project: Epiphany - 100% Complete Project: Endorphin Project: Paradigm - Xbox 360 Mod DAE_JA_VOO.com My Sponsors

13th Mar 2007, 08:20	#8
Jipa Licenced idiot. Join Date: Feb 2004 Location: Tampere, Finland Posts: 3,064	It depends on the heatpipes he's using. The ones with nothing else but water in them won't work, but there's also those that do. I don't know how they do it, but they definitely do. The problem I can see here is that unfortunately the CPU and the GPU aren't the only parts that heat up. I'd have one 120 mm fan in the middle of the back panel (none will even see it?) at very low speed so it would be inaudible. or atleast have some holes for the warm/hot air to escape from the case! Most of all I'm worried about the lifespan of the capacitor if it gets hot in there.. Nice and unique design anyways! __________________ Abit IP35 - E6750 - 8800GT 1024 MB - 2 GB 800 MHz - enough HDDs - 750 W Silverstone - CM Storm Sniper Asus P5Q-VM - Q9450 - 4 GB - 400 W Silverstone - Fortress FT01 AllTheMods - MetkuMods - LedCalc

13th Mar 2007, 03:09	#2
zachjowi Supermodder Join Date: Jan 2005 Location: WI Posts: 534	looks cool. good luck. I might have atleast 1 quiet 120mm fan

13th Mar 2007, 03:25	#3
Tursas What's a Dremel? Join Date: Feb 2007 Location: London <-> Helsinki Posts: 9	I have been doing some measuring and testing. Trying bit's different ways. Think three times, measure twice,cut once. I tend to haste with things Piling up the pieces with cardboard template. First thing is to cut the small pieces from the sides to fit the sidesupport later. This is the most annoying and tiresome stage. I still have not done all of them. Note the truly DIY cutting table/vice made out of gaffer tape and a vacuum cleaner to suck of deadly aluminium powder. I was thinking a long time how to bolt the heatsinks together until I came to this solution I will drill trough the heatsink and put a long rod trough them and then tighten the whole thing. Also the rod might transfer some heat (or not). I bought a new bench drill for this project (£100, a bargain). Biggest problem was to align two opposite holes (drill bits were too short to drill trough). Patience and measuring gave me good results. When drilling thick aluminium I found best to have high RPM and keep the drill bit lubed with WD-40. This will will eject chipping nicely and keeps the bit cool. After spraying my house aluminium chipping I have made one wing ready. Making the threads to 1/4" copper rod with die Tapping the holes for the threaded rod. Joining nicely. Ah, beautiful! three more to go....

13th Mar 2007, 05:33	#6
cyberspyder Canuck Join Date: Nov 2006 Location: Markham, Canada 43°, 40", Posts: 103	The aopen NB heatsink looks like some sort of word...

13th Mar 2007, 08:52	#9
ottzen Minimodder Join Date: Nov 2006 Location: N Sweden / W Germany Posts: 37	Why wouldn't heatsinks work if the mobo is upside down? O_o Not that I have any proof, but by the laws of physics any copper, aluminum, or steel rods will lead heat much better than the surrounding air, so there will definately be heat lead through there! Thing is though, that you'll get extreme hotspots with the mobo upside down, because hot air wants to rise and its so much harder to go anywhere if there's a mobo in the way Imo you should DEFINATELY put in som kind of fan. If you turn the mobo around you should also be fine with ventilation holes, but there's nothing like a low speed 120mm fan. But nice work with the drilling and sweet heatsinks you got there. //ottzen __________________ Finally!! --Intel E6320 w/ Sonic Tower \| Gigabyte GA-965P-DS3 Rev.3.3 \| 2GB G.Skill F2-6400PHU1-2GBHZ \| Gigabyte 8600GTS Silent \| Samsung HD080HJ (80GB) + Barracuda 7200.7 (200 GB) \| all warm and cosy in a Stacker 830 w/ Noiseblocker 120ies

13th Mar 2007, 09:36	#10
Jipa Licenced idiot. Join Date: Feb 2004 Location: Tampere, Finland Posts: 3,064	HeatPIPES, not SINKS __________________ Abit IP35 - E6750 - 8800GT 1024 MB - 2 GB 800 MHz - enough HDDs - 750 W Silverstone - CM Storm Sniper Asus P5Q-VM - Q9450 - 4 GB - 400 W Silverstone - Fortress FT01 AllTheMods - MetkuMods - LedCalc

13th Mar 2007, 10:06	#11
TMM Modder Join Date: Jan 2004 Posts: 3,228	Some heatpipes have wicks (sp?) in them which allows the liquid to still travel due to capillary action afaik. __________________ no, your face.

13th Mar 2007, 11:12	#12
Tursas What's a Dremel? Join Date: Feb 2007 Location: London <-> Helsinki Posts: 9	Thanks for the reply's guys. When I decided to go passive I knew I would run into load of problems. But because projects must be challeging I will keep it totally passive with no fans in it. The mobo and cpu produce very little heat, so I might get lucky. Heatpipes are made by Mcubed so they are the one with wick in it. So they will work in any angle. I will not have case totally enclosed. There will be some holes. Where and how big is up to the wood what im gonna use. Here is some layout I made this morning In a perfect world the cold air will come from the bottom grills and escape from top grills. I think I would make holes more narrow.... What comes to position of the motherboard. Its the case of "Form before Function". I could have it lying on the bottom with face up. But because I want to have DVD drive under the LCD display and this is the only way it fits. Again this is a situation what might change when I have computer up and running. Front piece is the last thing I will do.

13th Mar 2007, 13:58	#13
Burnout21 is true bit-techer! Join Date: Sep 2005 Location: Nott's Posts: 4,862	dude this HTPC will weigh like 20Kg!! at leat no one can run off with it quickly!! __________________ DFI P45-T2RS Plus, Q6600, 4GB Reaper HPC, GTX280 & FX3450, X-Fi Xtreme Music, 1570GB Storage

13th Mar 2007, 14:07	#14
guysy1110 Multimodder Join Date: Feb 2007 Posts: 97	This is a sweet idea. I think you will be able to keep it passive if theres no marjor gaming, apps running all the time... i would love to have something quiet when im watching a film lol. Good work.. keep it up

13th Mar 2007, 15:34	#15
Bas van der Werff Multimodder Join Date: Feb 2007 Location: Netherlands Posts: 228	Sweet idea where did you get those heatsinks? __________________ Radical Fusion update [9th June 07] If you're putting more blood into you're project than sweat, double check that you're holding the tool correctly.

13th Mar 2007, 17:36	#17
Tile Banned Join Date: Jun 2006 Posts: 376	Deleted Last edited by Tile; 3rd Nov 2008 at 00:05.

13th Mar 2007, 18:48	#19
rowin4kicks Hypermodder Join Date: Feb 2006 Location: Windsor, UK Posts: 761	wow i love the wood and heatsink mix! very origional! i love the design idea as well, but maybe having a low under volted 120mm fan at the back blowing in air which can escape throught the vents at the top would just improve the lifespan of the computer or maybe a fan you can turn on when it gets too hot inside anyways good luck and its you decision! __________________ Penguin v5.0 on it's way... AMD Phenom II X4 955 - 4Gb 1600Mhz Corsair Dominator - XFX Radeon HD 5850 - Corsair HX650W - 500Gb Samsung F2

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