Scratch Build – In Progress Homemade Alu case /w copper highlights. FINISHED.

I will post links to the updates here so you don't have to go searching through pages of text to find them:
1: Got materials and started frame construction. 1-11-08
2: Completed frame construction and got first package of stuff 1-13-08
3: All panels cut to size, new stuff in the mail and first panel screwed to frame 1-15-08
4: Sacrificed a small goat... I mean old case to get a back panel 1-17-08
5: Made a res and attached the back pane 1-19-08
6: Completed the inner top panel and put in the mesh 1-20-08
7: Working on a new reservoir 1-21-08
8: Finished res and started work on mobo tray and dvd drive casing 1-25-08
9. work on buttons, wiring, bottom case "cover" 1-26-08
10. work on hdd mounts 1-28-08
11. Finished HDD shelf supports 1-31-08
12. Small update of lower-inner panel PSU intake hole 2-4-08
13. Drilled a billion holes, cut hole in side panel for window 2-5-08
14. New front and top fan grill 2-17-08
15. Attached casters and drilled some holes. 2-20-08
16. Finished the back panel. 2-21-08
17. Installed computer components, leak testing. 2-22-08
18. Turned it on for the first time, did more misc work. 2-23-08
19. Completed! Final photo shoot. 2-24-08


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It's been quite a while since I finished my last case mod in 2004. Here are a pic or two of my old case, so you know where I'm coming from.


It was featured on Bit-Tech's front page back in the day.

Anyway, on to the new stuff. I have been browsing the project log forums here on and off for the past 4 years and have finally gathered my ideas. Some of my inspiration comes from Apple Core 2 Duo and various other mods.

My new case will be aluminum and built completely from scratch. There will be polished copper highlights in choice locations. I intend on polishing the aluminum on the front of the case to a mirror finish. Once the case starts to shape up, depending on how it looks, I might polish the sides of the case as well.

Here are some drawings I've been working on in SketchUp for the past few days. The main dimensions are 18" deep, 8" wide and 22" tall.








Today I placed an order for the aluminum sheet and aluminum square tubing. I ordered 18 square feet of aluminum .050" sheet, 42' of 3/4"x 3/4" square tube with 1/8" walls, and 2 square feet of .0216" copper sheet. Hopefully that should be enough.

The sides of the case will be perforated (lots of 1/8" holes) to allow air to be drawn in. The three 120mm fans on the radiator will take care of pullign the air through the case.

The computer will utilize parts that I already have. I will however buy a new radiator, fabricate a new reservoir, buy a fan controller to strip down and stealth, hide some usb ports somewhere and buy some new tubing. The design is by no means final; i've redesined it several times over the past few days. It may look sparse at the moment, but just bear with me here.

Comments?

 

looks nice, isnt you gonna have an dvd player? nice Sketchup gonna follow this project

 

mmmmmm.....copper..... I can totally dig it man, polish the whole case including the copper. That would look awesome.

 

Since my comp is 3-4 feet away from my desk, I just modded an external drive for my old case. Here's pics of it. I plan to do something similar with this new one.

 

I'm always interested in any project where the entire case is designed and made... Looking good! How do you plan to finish the alum... polish or brushed?

subscribed!

hagatha

 

I plan on polishing the front to a mirror finish and maybe leave the sides with a brushed look. All of the copper will be polshed to a mirror finish.

 

Nice to see another wood modder!!! I like the new design as well.

 

looks pretty good so far

 

-Throwing some design ideas at you here. You could:
Separate the copper from the aluminum with some plexi and add some optional back lighting too.
Wrap the copper around the corners with a curved bend to break up the shape of the box.

 

Thanks for the suggestions. I don't think lighted plexi would go with the theme but your other suggestion sounds good. What exactly do you mean though? Make the corners between faces curved by using copper? You might be on to something, but let me give you an idea as to the cost of copper.

I ordered 2 2'x4' 0.05" Aluminum sheets for $40 (20 each). I ordered 1 copper 1'x2' 0.0216" sheet and it was $26.92. so for 1/4" of the area and 1/2" of the thickness, it cost more.
At the prices I paid:
Au is $0.35 per in^3
Cu is $4.33 per in^3

thats more than 12x as much. (not to mention I had to order the copper online and pay $13 shipping because I couldn't find a local supplier as I did for the aluminum.)

 

i see you burned the side of the front CD-drive. Rookie mistake. One of the things ur NEVER suppose to do when working with wood

 

? I didn't give a crap because it's not visible.

 

That WAS a pretty low blow comment.

To be honest, not giving a crap about your work just because it doesn't show is not the one of the characteristics of a dedicated craftsman. I think you should always care about the quality of all of your work.

That's my opinion.

Peace.

 

There's a difference between doing good job and being obsessive about making it perfect. If you want to know the truth, I sanded it down too far trying to get rid of the burn mark and it only got worse and shorter and shorter. So I stopped before I sanded too much off and had to remake the drive cover completely. So take your opinion some place else kthx.

I can't believe you two are making a big deal out of that little burn mark. And like I said. It doesn't matter; it is not visible. That'd be like... polishing the bottom of your car or something equally stupid.

 

Guess what? It IS visible.

Regardless, if that level of work allows you to sleep at night then peace be with you.

ALL of the great, great mods are loaded with insanely obsessive attention to detail. That is usually the difference between great and just a "good job".

 

My case is made to my standards.

 

OK

Good luck with your project.

 

I don't understand why y'all have your panties in a twist concerning a BURN MARK.

Chill out.

Nice design, btw. It's totally pimpin'.

 

Too right,

and if i was you legoman i would't bother posting here in this forum anymore, find another one without so many 'tards

 

Welcome to the forums