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Scratch Build – In Progress Project: EVGA Classified SR-2 Case [Completed]

Discussion in 'Project Logs' started by Spotswood, 3 Apr 2010.

  1. skreenname

    skreenname SFF Forever

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    Why the painters tape on the drives?

    Excellent job on the 5.25 bays.
    Beautifully snug.
     
  2. Spotswood

    Spotswood Custom PC case builder

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    The tape is there so the face plates don't get scratched. :thumb:
     
  3. voigts

    voigts What's a Dremel?

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    I appreciate you going into more detail on how you are going about routing out all of this stuff. I understand now what you are doing and how you are doing it. Very nicely done. Your router work comes out like it was done by a CNC. Where are you getting your router bits from? Most of the bits I see say they are for wood and not for metal. Those bits have got to be pretty hard to be able to do all of that metal cutting.
     
  4. Spotswood

    Spotswood Custom PC case builder

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    Most of the routing has been done with standard woodworking two-flute, carbide, pattern/flush trim router bits (I ignore there intended use :D) All of the bits were purchased at mlcswoodworking.com (mostly for their free shipping). If doing simple trimming/ripping I spare the woodworking bits and use standard end mills (from mcmaster.com):

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    The only tips I can offer is to move the router very slowly (to avoid heating up the router bit or melting the aluminum) and to make your cuts in two passes. The first pass with a pattern overhang bit (#6504) which leaves a 3/32-inch overhang, followed by a second pass with a standard flush trim bit.

    With all of the aluminum I've cut for this case, only the overhang bit is noticeably duller. :thumb: Which doesn't matter one bit (pun intended) because the slightly ragged cut gets cleaned-up on the second pass anyway.
     
    Cheapskate likes this.
  5. voigts

    voigts What's a Dremel?

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    Thanks Rich. I've ordered from mlcswoodworking before, and their router bits are great. Mcmaster is a wonderful place for the modder. They have so many different things you just can't seem to get elsewhere. I may have to pick up one of those end mill bits the next time I order from them.

    I think what I will probably do is to use my scrollsaw to rough cut out any areas, and then use a flush trim bit with jig to cut the last bit to get a smooth edge. I picked up a 1/2" flush trim bit at Sears today while I picked up some scroll saw blades. It seems to me that it would be easier to do it this way than to use the router to make the rough cut as well.
     
  6. LooseNeutral

    LooseNeutral What's a Dremel?

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    Just picked up on your project. Great work, She's a big'n! I also appreciate the detail of your log and the tips your providing. Got ya bookmarked :)
     
  7. Spotswood

    Spotswood Custom PC case builder

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    Filed, sanded, scratched and test assembled the 5.25-inch drive rails to the PSU mounting plate.

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  8. Unicorn

    Unicorn Uniform November India

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    Outstanding work spotswood... I'm subbed because I'd like to have a go at my own SR-2 enclosure some time next year, once the initial launch prices have died down and the hardware becomes more affordable :)

    Subbed :thumb:
     
  9. Spotswood

    Spotswood Custom PC case builder

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    Next up are the 5.25-inch drive rails for the bottom mounting plate.

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    These (unfortunately) required a ridiculous amount of time to complete.

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  10. Spotswood

    Spotswood Custom PC case builder

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    The fan covers are the last of the aluminum parts (yippee!):

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    I used a 1/2-inch router bit and an old router template to cut the wiring and tubing slots.

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    Now I just need to (re-)prep everything for powder coating and send them all off to the painter's.
     
  11. Cheapskate

    Cheapskate Insane? or just stupid?

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    You make it look so easy. I mangle stuff when I use a router.:hehe:
     
  12. Spotswood

    Spotswood Custom PC case builder

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    It happens to me too sometimes.

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    :wallbash:
     
  13. merple

    merple What's a Dremel?

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    wow this case is going to be a beast.

    That image of it with the ascension is :jawdrop:
     
  14. Editor22

    Editor22 E22 | Hex-Gear

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    Had to search for hours to find this log again... your pictures detailing router jigs are priceless :D any chance of making a tutorial sometime? :idea: o and wheres the updates :eyebrow:
     
  15. corsair_reventon

    corsair_reventon What's a Dremel?

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    Looking great so fair man
     
  16. Spotswood

    Spotswood Custom PC case builder

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    Its time to start making some sawdust!

    Ripped and thickness planed some 1x8-inch red oak into 1.5-inch wide boards to be used as the lower case face frames.

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    Pre-stained the wood and drilled the pocket holes.

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    The bottom of the case was also drilled for pocket screws.

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    Face frames were assembled with some glue and screws.

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    A homemade depth gauge was fashioned from some rubber stoppers/bumpers.

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    The depth gauge was used to drill holes for #8 threaded inserts on the inside of the face frames. A hex driver made the task of screwing the inserts into the wood easy.

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    The lower case face frames and bottom all assembled.

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  17. Spotswood

    Spotswood Custom PC case builder

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    The top case was built the same way as the bottom.

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  18. voigts

    voigts What's a Dremel?

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    Nice work Rich. Looking very good.
     
  19. Spotswood

    Spotswood Custom PC case builder

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    Powder coating came back this week.

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  20. Daydream85

    Daydream85 What's a Dremel?

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    Coming along nicely! thats going to be one massive but stunning case.
     

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