Scratch Build – In Progress Project: Aluchill - Final pictures 20/09-09

Sponsored by Alphacool:




And a special thanks to Tom @ Chilled PC

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Links:
Update #1 (Frame constructing and diy)
Update #2 (Frame finished)
Update #3 (Panel cutting)
Update #4 (Panel cutting & mockup)
Update #5 (Panel cutting & mounting)
Update #6 (Panel mouting, PSU opening, tray slide)
Update #7 (Back panel finished & WC stuff)
Update #8 (Shape complete, outer panel cut and bent)
Update #9 (5,25 Holder and Diy)
Update #10 (Front construction)
Update #11 (Front Completed)
Update #12 (Rad mount and internal cover)
Update #13 (Fan Grills and LCD-bezel)
Update #14 (Detail work before powder coat)
Update #15 (HDD-suspension and details)
Update #16 (Powder coating)
Update #17 (Finally! Assembly line!)
Update #18 (Assembly continues)
Update #19 (EYE CANDY! Internal build 98% finnised)
Final pictures

About the project:

So guys, this is my first scratch build ever. I've always felt quite unpleased by modding a pre-made case so this should be very exciting.
As you have probably already realised by its name, this mod is going to be built using aluminum materials only. It's a nice material to work with, and its fairly light weight.
It is going to be packed with high-end water cooling and some nice components.

Hardware:
XFX 780i SLI motherboard
Intel QX9650 CPU
4x 1gb OCZ FlexXLC 9200 memory
2x 8800Ultra in SLI graphics cards
Corsair HX1000 power supply
Creative X-fi Fatal1ty Titanium sound card
WD 36gb 10k raptor
Samsing 400gb harddrive

Watercooling:
EK Supreme CPU
2x EK-FC8800 GTX/Ultra - Acetal
EK-NB 780i - Acetal
EK 780i Mosfet block
Thermochill PA120.2
Thermochill PA120.3
2x DDC3.2 with XSPC laing top
Feser compression fittings

 

Update #1 Oct 31 (Frame constructing and diy)

So now it starts. Here are some pictures for you all.

Sketches:






The motherboard tray. Produced by Lian-li. And of course it's made out of aluminum.


The water blocks I will be using.


First I'm going to build the frame. It is going to be built using 15 x 15mm solid aluminum bars.
I'm going to join the bars using M5 hex cap screws.
The plan:


And after some cutting with the mithrill saw I got all the pieces I need. The cuts and the bars are very nice and straight.


In order to get the right angle I need, which is quite important when building like this, I'm going to use a 90 degree clamp.


I will drill the holes using this drill:


Start out with drilling the hole so that the hex screws will be counter sunk nicely into the bar.


Directly after drilling


And after that I drilled the hole for the screws thread.


Clamp two bars together like so:


Then manually drill the hole in the second bar which is going to be threaded.


Tapping for M5 bolts:


Some lubricant makes the process much easier:


Then screw the bars together with the hex cap screws and we get this:


Repeat this process 10 times and you have the top of the frame done


Repeat the process another 10 times and you have the basic frame done.


It is not finished yet though. Have some bars left to mount.

Got a package from Alphacool containing a nice little display





Thanks guys! Should suit this project perfectly!

 

Uuh lotsa aluminum so far, so good, keeping an eye this. Good luck!

 

oooo nice start!

I first thought it was a mod on a current lian li case from the renders, but its scratch built!

 

hehe
very nice !!

 

nice start, I like the plan of the potential outcome

 

Thanks guys!
bigsharn, the outcome will probably be very similar to the sketches. Of course there might be some changes but the overall design is going to be like it.

 

Wow that is some neat frame building... How much are those solid Alu profiles weighing? Despite being a light metal, I can't see 15mm x 15mm solid alu being light...

Laz

 

Lazuli: According to the place where I bought them from. A meter of the 15x15mm bar weights about 0,6kg. I've used about 7200mm so with some easy calculations, the frame should end up weighing about 4,3kg.

 

i like the design, did you buy the lian li mobo tray by itself?

 

Nice! Subscribed, because swedes and danes should support each other!

 

A very good start. I love the look of the CADs, very interesting and effective.

 

Update#2 Nov 4 (Frame finished)

Hey guys! Time for an update again.
Went to the workshop and spent a couple of hours finishing up the frame.

Got the part done for the middle floor. The floor will separate radiators and PSU from the main computer components.


Took a photo of a section of the frame with two joints. Just to give you a hint of what kind of precision this is.


And finally got all bars together and finished up the framework.




Next step will be to cut all the panels from this "little" piece of aluminum sheet.


All the bends will be worked out using this brand new brake.


Comments are welcome!

 

The frame looks very good, very strong. How much does it weigh?

 

#14: see #9

 

Update #3 Nov22 (Panel cutting)

Hey guys. Got some time to work on the project so here is an update for ya.

I laid the sheet metal on top of my workbench in order to be able to work with it.


Going to cut out some panels using this jigsaw


New blades for cutting in metal


I problem that I ran into was how to make the cuts as perfect as possible. In order to solve this I took a straight piece of wood and clamped it on top of the panel. Then I just followed the wood with the jigsaw. Think it worked pretty damn good.


Like so:



And after some sanding and filing to smooth up the edges I got this:

Pretty good huh?




Got two of them


Just need to saw out the other panels which probably wont take too much time.
Made a little video for you showing the process of the sawing:

What do you think?

 

looking nice so far !
great tutorial also, never thought about cutting like that.

 

nice stuff, is this the standard render output from sketchup or some kind of plugin?

 

nice job so far! i love how u did the frame out of solid pieces instead of hollow pieces

 

Update #4 Nov23 (Panel cutting & mockup)

Dark~3nergy: Thanks
FrooP: It's standard "render". You can choose to display shadows etc.

Yet another update!

Got to love weekens Went to the workshop and finished the floor-panel and the middle-plate.

Pretty good precision huh?


Had to do a little "mockup"




Motherboard tray


Feels good to see things fit together so nicely




The parts so far (Yes, I love smudging them panels with my fingers )


More comments guys!