Case Mod - In Progress IMPORTANT QUESTION "OVERHAUL", Update 9: Aug 6, 2007

Hi guys I'm new here (thanks to Rich Taylor for his help fixing my registration issues).

Anyways, I have OLDOLD Dell XPS (think 1999) that has what I think is an amazing chassis. Its not necessarily modular or tool-less but its small yet still fits a standard ATX motherboard. It's 1mm steel and pretty sturdy.

So... I have pictures of how I stripped the chassis of all the PVC parts. I'll post those soon enough. (I'm still trying to figure my way around this forum) Right now I'm drawing out blueprints for the new side/front panels.

I have a few questions since I'm a newbie:
-Can someone point me to a guide about handling/manipulating/cutting plexiglass?
-Also can someone point me to a guide about steel?
-What would be the best dremel bits to use when handling plexi/steel?
-What is the best company for laser cutting (West Coast USA)? Is there a DIY alternative?
-What program do you guys useto make 3d sketches of your projects?
-How would i go about contacting potential sponsors? (In case it happens to turn out better than the crud I'm expecting, prolly wont happen)

PICTURES!
I had to strip this dusty mess of its parts and panels

Dell has instructions on its site to remove *most* of the parts
The fan and mounting system after removing the PIII slot

fan removed, I'm going to refurbish and re-use this since Dell supposedly purchases high quality fans

This is the front I/O assembly / HDD mount (not too much of a hassle to remove)

Here I have changed the drive cage to make it mount horizontally. This discovery prompted me to start this mod. This chassis will be converted into an HTPC

This is a picture of everything completely stripped

At this point an ATX motherboard fits as well as a standard ATX PSU.

 

sketchup

Clicky

 

about the guides, you don't really need someone to look for you. google is your friend, look here:
www.thebestcasescenario.com for guides.

This is in the wrong section, untill its a worklog this sh ould be in the modding sectin not here!!!

 

pictures are being uploaded as we speak.

I have an update already, i just need to take some pictures.
What I have done:
-Refurbished the Case Fan
-Cut the rear I/O panel to fit a standard ATX (not smooth yet)
-Drawn up some blueprints to give to TAP Plastics

What I need to do:
-Finish the blueprints
-Buy new dremel bits (plus an organizer, I inherited the messiest dremel kit ever)
-take picture of the tools I have to show you guys and get reccomendations from you about other stuff
-buy SECC to make a new I/O panel and top panel and front panel.

 

***UPDATE2***
So the real work has begun... a while ago... just never took pictures...

Anyways one of my first tasks was to use my Dremel to cut off part of the back near the I/O plate so a standard ATX board could fit.

I still need to sand this baby up

... it was my first time, felt good!

I took measurements of parts using my handy measures
Red (got him free)...

...and Stanley (inherited)


I'm going to replace this "grilled" portion with two 120mm fan mounts here...

^...i should fix up my blueprints so they could be used for WCing in the future (although I don't plan too).
***QUESTION: Does anyone have dimensions for a dual 120mm WC radiator?***

Speaking of blueprints, I've made one up for my acrylic front panel...

^I hafta take this into TAP Plastics tomorrow

Remember that fan I showed you?
Well i refurbished it... took a vacuum, a cloth and some oil and patched this baby up.

^It's going to remain as the rear fan of the system.

And this fan...

... is just keeping me cool in this weather (not that hot actually...)

Hey I need to come up with a title for this mod. if you could help me out that would be sauce-ome

 

http://www.swiftech.com/assets/images/products/MCRad-220/mcr220-SCHEMATIC-708X749.gif

 

is there zero space between the two fans on that system?

 

Sandwich, the fans are set tightly together on the rad, so I assume it answers your question. It's only the space BETWEEN the screws that is 19mm wide. Happy modding, looking forward to see your finished case

/Frido

 

Hey thanks!
Well here is UPDATE 3!

Today I went to TAP Plastic (my local plexiglass store) and found out that for cutting.... they are completely backed up for a good 3 weeks. So i plan to go to another one of their stores or online (either TAP or another source). Also they do not take metric measurements in-store, i have to check online but im sure they don't either. That means i'll have to either do the fan cut-outs myself more simply revert down to an Imperial-sized rectangle.

I need to buy some scraps from them (only a $1) so i can practice with stuff. Ill take some more pictures of something to keep you guys entertained... stay tuned...

 

Update 4:
Introducing the Cost Counter
Today's Cost: $83
Total Cost so far: $83
Proposed Budget: $200

I purchased the acrylic panels (3 plain, 1 with cuts for Drivebays and Fans, 2 pieces of scrap) I need. The total was US$83 [is that a good price?]. They are Due on Friday Evening.
Everything went smoothly except... i had to put a 1/2 inch border all around the plexi panel I'm using for the front panel... this is because they can not do some of the cuts without risk of snapping the acrylic. They could have done it with a laser but it would have cost me a bundle more than I have already spent.

So my predicament is cutting off that extra half inch. The guy at the store said if i bonded a sheet of metal over it then i could cut it no problem since the plexi wouldn't be able to shatter. That should work right?

 

thats o.k. price, but it depends on thickness. Whats the thickness?

 

Firtsly, welcome to the wonderful world of modding (WWD )

Depends what Rad you would be using. If you are thinking about water cooling in the future you might want to look into what rad you might purchase and make sure it will fit snugly (i.e. not just the fans positioning but the actual placement and attachment of it). In terms of performance Thermochill rads are considered by almost all to be the best out there right now but they are relatively more expensive than Swiftech's and taller (thicker).

Mod on!

 

well most of the cost is labor ($49)
one of the panels is 1/4 inch
and the other three are 3/16 inch
scraps were about 75 cents each

so i guess about $34 for the main material... ugh

im starting to think i made a mistake.. i should have gone with ABS...

 

hey is the technique i posted Four Posts up correct? with metal and plexi bonded.

 

nice idea.... nice work... good luck brother

 

UPDATE 5!
Cost Counter: $85

Picked up my plastic today... it looks pretty good. There are a few things i'm disappointed with though.

Here is everything i picked up today. All are glossy opaque black.

^you might not be able to notice but the top edge of the rectangular cutout isn't even. It can be and will be covered up but next time I'll be going with the laser cut.

Here is a close up of the rectangular cutout (bottom right corner)

^The angles are rounded. I guess 90 degree edges can't be done without a laser. I can prolly fix it up myself

Some great news that leads me to believe that the 92mm fan was made with Imperial measurement in mind.

^the 92mm fan fits perfectly

^room for two! plus a little bit of room for dual 92mm Radiators.

A little teaser of some sketches for logos. (yeah they suck)

^I'm probably going to paint them on since I have opaque Plexi.

Well I have to take a short Hiatus on this project because on Sunday my fam is having a party and I need to keep the house and everything clean so that sucks completely I'll be working on logos and buying drill/dremel bits + sheet metal in the time being.

 

I was wondering what is a good place to buy switches (ie power and reset) from? I was thinking Radio Shack but I don't have a very good one near me.

 

UPDATE 6: Bought more materials still on haitus

Cost Counter:
12" x 18" 26GA plated sheet metal - $5
426 Reinforced Dremel Cutting wheels (5) - $10
Total Cost: $100

Yeah i bought new cutting wheels and some sheet metal today. I need to find a place that sells aluminum cheap cause... it's really really expensive at OSH ($25 for 12" x 18").
I cleaned up my dremel box today, found 3 420 cutting wheels, 1 grinding bit, and one thick cutting wheel. I also found some polishing stuff but the rest were useless sanding bits.

Any one know where i can get sheet metal or Dremel/Jigsaw bits for cheap (online is A-OK)?

 

nice work you good at this

 

www.onlinemetals.com

not cheap, but if you have plenty of support, thin stuff will be o.k.(.04 or .032 is ok, i prefer .04) its like 12 bucks for 24x24... not cheap, but not expensive either