Scratch Build Project: Aluminum Water Cooling Case

[Waynio]

Every time I look at the side panel mounting method I want to do that reminds me of how nice & easy they mount on/off, could do it 1 handed on my old Lian-Li, my favorite panel mount method when done right like this.

And cheaps fix is so true, original version & fixed version.

[Spotswood]

Another router template was made to cutout the areas for the PSUs out of the back sheet. A guide was clamped to the bottom of the template to keep the cutouts perfectly aligned along the bottom.

[Waynio]

Nicely done & all these jigs you make, do you keep them aside labelled for future use to make things quicker?.

[Furball Zen]

Its amazing the n00bs who cant figure out that this is not his case lol.

[Spotswood]

Originally Posted by Waynio

Nicely done & all these jigs you make, do you keep them aside labelled for future use to make things quicker?.

Yes, usually I will save and re-use templates. But in this situation I could make the opening larger (because of the extra room) to avoid having to square-off the corners.

[Mosquito]

I'm quite glad to see this going again :-)

Can I ask what speed you use with the router? I have two routers, one variable speed, and one non, and I was thinking about using the non-variable speed one for this.

And if I could also ask what bits you use? (You said 3/16" and 1/4" down cut spiral, but I was wondering about brand)

[bluc]

Awesome stuff amazing craftsmanship and great work with the router. I have not been brave enough yet to run a router through aluminium.

[kinghong1970]

Originally Posted by Mosquito

I'm quite glad to see this going again :-)

Can I ask what speed you use with the router? I have two routers, one variable speed, and one non, and I was thinking about using the non-variable speed one for this.

And if I could also ask what bits you use? (You said 3/16" and 1/4" down cut spiral, but I was wondering about brand)

and do you use any lubrication?

[Waynio]

Rich pointed this beauty out to me when asking him some other time, not sure if he got around to getting it yet though, looks excellent for routers.
http://www.vhipe.com/product-private/SuperPID.htm

[jeckulz]

Aaaaaawww yeaahhh.


Superb work to now man, keep it up, you got a sub!

[Spotswood]

Turned out that I needed to cut one more slot out of the bottom shelf. But the last time I used my wooden "small slot" router template, I somehow managed to crush one edge, so I quickly cobbled together a new out of some left over t-slot extrusion. I'm really loving using these t-slot extrusions to make router templates - fast and accurate!




Here's a teeth-shattering video of me cutting out the slot:

[matt...]

This looks like it will be awesome!

But seriously, 3 x 140x4 radiators and 1 140x3 radiator - are you trying to cool Africa??!?

[SpleenBeGone]

I love how elegantly simple your construction methods are.

[Spotswood]

Originally Posted by SpleenBeGone

I love how elegantly simple your construction methods are.

Wow! That's one of the nicest compliments I've ever received. Thanks!

One of my motivations for publishing a build log is to convey how relatively easy it is to craft a case out of aluminum. Seriously, all you need to invest in are a drill press, a router, and some hand tools. (Unless your Attila, in which case, all you need is a hand file).

[SpleenBeGone]

I've actually been considering making a case for a while, but for some reason it never occurred to me that I could cut the aluminum with my router. The way to get nice clean cuts like that was always the biggest drawback for me, as I never had access to a CNC, and dremel and nibbler cuts look bad IMO. When I build a new rig, I'll be making a custom case as well using your method, and will be following your threads for more tips.

Edit - Also, where did you get that self centering vice? I could get so much use out of one of those for all my projects.

[Spotswood]

Originally Posted by SpleenBeGone

...

Edit - Also, where did you get that self centering vice? I could get so much use out of one of those for all my projects.

I got the vice from Grizzly. And is of better quality than most other tools from that site.

Yeah, you'd have to kill me in order to take away my vice.

[SpleenBeGone]

Thanks for the link, I'll be ordering one of those.

[Spotswood]

Performed the mind-numbing task of fastening the bottom and top sheets to the case frame via flat head socket cap screws. Through and countersink holes were drilled into the sheet and transferred to the case frame via a self-centering counterbore drill bit.







Bottom sheet all fastened:




And top sheet all drilled out:

[FatPandas]

Originally Posted by Spotswood

...four PEM cinch nuts were pressed into the interior side of the .10-inch thick aluminum sheet. I love these nuts because they make quick work out of adding some threads to sheet metal.

Ah - that's what they're called. Cheers man, you saved me a lotta headache

[Spotswood]

Drilled out the holes for the vandal resistant switches and fastened the front sheeting to the case.