Scratch Build – In Progress SP1's Project.

I am going to put all the parts together using countersunk rivets.
I used a large drill bit to countersink the hole.

All done

These are countersunk 4mm steel rivets.
I tried the rivet on a sheet of scrap steel.
It fits

 

I had some more parts made all in galvanized steel apart from the biggest piece which is
in 1.2mm aluminium,this makes the top,bottom and one side of the case.

Fits together well.

 

I clamped together and drilled through both steel and aluminium parts

Put a nut and bolt through each hole as I went around
Back part done.

and with the front end done you can see it looks more like a case

 

This bracket is for a slim DVD Writer

Drive fits perfectly

Clamped in place and drilled holes

Bolted in

 

Are you using galvanized steel? It has a weird looking finish on the metal. Maybe a little bit of polishing might look kinda neat on that.

 

Er, I didn't think about that,I might have to use filler and sand it down. Even if I polish it it will go dull after a while. I am using galvanized steel,
steel is so much stronger than aluminium.
Started cutting a hole for the DVD Drive





Filed the edges

Done

 

What type of dremel disks are you using for galvanized steel?

 

Props for the dremel action shots!

 

The first hole I cut I used the 409 disc.These are thin and brittle and when they are half the diameter left wear
down fast. The last holes I cut a groove with the thicker 420 disc but if I tryed to cut all the way through it
was hard to control so I switched back to the 409 which sliced through what was left quite quickly. I got these
426 reinforced discs I will try. 409 and 420 discs are 24mm diameter,the 426 disc is 32mm.
Until I come across this and similar forums I had no idea about cutting discs and what you could do with them.
I am learning as I go.
Another thing you can do is use a thicker disc lightly against a the sheet metal edge to take away material
though I still finish with a hand file. It is a lot quicker than using a grinding wheel with a lot more control.

 

Files are the best for finishing. I have used all three of those, and I must say that they each have their own use. I would also recommend the Dremel Diamond Blade(545 I Think). Its great, and lasts a decent time. A little longer than the 426 iirc. But kudos on the trial and error with dremel disk, it's the best way to learn.
I Like the case how its going. It has a bit of an industrial theme right now, and looks sturdy enough to survive a few falls(even if the components don't)

 

The mother board tray won't fit so well against the back of the case.
Because of the rivets I put sheet metal to fill the gaps. I glued all the
parts together using exposy. First time I used exposy, doesn't work
with steel well. I have drilled out the rivets to take the pieces apart.
Guess where the wood pieces come from?

This metal is not adding any strength apart from the right angled piece that would fit under the PSU
but most cases are made from 0.6mm or 0.8mm steel and the steel I am using is much thicker and
stronger. I will save around 350g taking it out.

 

I got another tray made but this time in 1.6mm steel. It is a lot heavier than
the 1.2mm one.
Started cutting the PSU hole.





Marked out the hole for the motherboard tray I'll cut this tomorow

 

Started cutting



Takes more time cutting through but getting there

Thicker steel,a lot more metal dust than before the Dremel's fan blows it around.

Filed the edges

 

I can only imagine all the terrible noise involved in those action pics... I tried cutting a small hole to 2 mm thick aluminum with my rotary tool and even it seemed to make just too much noise.

 

You are right. Steel takes more time to cut and creates a lot noise.

 

It has been a while since I have done some work on this case,I'm sorry.
I spend most of my time working and do this in bits.

I had to drill the holes again to fit the back to the aluminium piece.


I am going to use this steel sheet for the door.


With these hinges


Which I have fixed to one side


being slightly too big I have to trim the sheet down a bit.


And I will attach it to the back


Fitted on, the door does not work very well. When the case is on its side it
scrapes against the top edge, and when I stand the case up the door scrapes
against the bottom edge.

I'll see what I can do to fix it.

 

Nice job and good photo's

 

Realy nice dremel action pictures..... I lik it =)

And of course nice casemod =)

 

Dude you the king of the fire dremel. Lol I like the way that fire come away from the disk nice work

 

I have made this case too small, I don't think I will be able to fit all I want inside. I am going to start again.
I have this Lian-Li motherboard tray.


As you can see it is a full ATX tray.
I have drilled out the rivets to separate the motherboard from the back panel.




I need to get some more parts together.