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Scratch Build – In Progress project [NS-5] by Rankine

Discussion in 'Project Logs' started by Rankine, 26 Mar 2011.

  1. Rankine

    Rankine What's a Dremel?

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    Hi everybody!

    I just want to show you my first creation: this is a self made case, totally projected and assembled by myself, in the spare time across 2009 and 2010. It's made by 3mm thickness alluminium panels, die cast and wood.

    Actually mounts a miniITX Zotac mainboard, an old E500, integrated VGA, a sata DVD optical drive recycled from a notebook, an 80 GB sata Hard disk, an 800W Corsair power supply, one DCC500 Laing pump, a 360 stealth radiator, one EK reservoir and some other smaller parts.

    I hope to find some time to write the worklog, but now i'd like to show you how is the actual configuration of my creation: here you are!

    http://www.youtube.com/watch?v=8HITUi_jRzIù
     
  2. Rankine

    Rankine What's a Dremel?

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    This project was inspirated by the movie "I,Robot".

    The mechanics of the robot Sonny inspired me with the design of the shapes. The main purpose of this study was to enhance the mechanical appearance of the structure, not focused on hardware components.

    Let's start with the worklog:

    I started the construction of two semi supporting frames. First of all, i cutted from a 6mm slab of plywood, four identical shapes:
    [​IMG]

    After some sandpaping, here is the result:
    [​IMG]

    Now,on the two outer panels were glued some details to give volume to the structure. I got two rings of plywood:
    [​IMG]

    [​IMG]

    et voilà!
    [​IMG]

    Going on with the glueing:
    [​IMG]

    [​IMG]

    These are the glued details:
    [​IMG]
     
  3. Rankine

    Rankine What's a Dremel?

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    Then I proceeded to paste shims (derived from a cross section 20x10mm stick) along the outer edge of the two shapes, then glue the respective inner panels:

    [​IMG]

    After the first coat of filler, here is the progress of the work:[​IMG]

    Finishing filling:
    [​IMG]

    And here's the result after a pair of coats of primer:
    [​IMG]

    [​IMG]
     
  4. IvanIvanovich

    IvanIvanovich будет глотать вашу душу.

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    very interesting. you did some good work there.
     
  5. Rankine

    Rankine What's a Dremel?

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    Thanks, Lysol!

    I glued in the inner side of the two frames a 3mm aluminum panel in order to give more strenght to the whole structure:
    [​IMG]

    Go forward with the support of the motherboard. The choice fell on a DFI P55-T36 MI, mini-ITX form factor.
    At first I cut 8 studs from a bar of aluminum 8x8mm, then I made to one side of each bar 2 holes for screws M4, while to the adjacent side I made other 2 holes for the M3 screws.
    [​IMG]

    Done this, I cut two plates 180x180mm which, once fixed together with studs, will be the support for the motherboard. Between the two plates will be placed the wiring and the pipe tube for the liquid coolant. On the back plate will be mounted the EK bay trap.

    [​IMG]

    These are the two frames and the motherboard support assembled:

    [​IMG]

    [​IMG]
     
  6. Rankine

    Rankine What's a Dremel?

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    I wanted to paint the two side supports by creating an effect "cast iron painted" with the typical porous surface.

    I first covered the surface of glue, then I covered it all with a metal sand for sandblasting:

    [​IMG]

    [​IMG]

    Once dried everything, I painted the sides covered with sand with matt black colour. Here's the result:
    [​IMG]

    [​IMG]

    This is the result with the two supports painted and mounted:
    [​IMG]
     
  7. Rankine

    Rankine What's a Dremel?

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    It 's time for hard disk and the DVD drive.
    The project includes a sata slim DVD recorder brought from a notebook and a 80 GB SATA hard disk.

    To create the support, I cut three identical sheets of aluminum and
    I practiced into them the holes for DVD and hard disk. Then I
    assembled it all with two threaded M4 rods, spacing the 3 plates
    with 4 tubular steel of 8mm diameter. Everything was bolted
    with nuts. Simple, but i like it....
    [​IMG]

    [​IMG]

    Assembling test:
    [​IMG]

    The support was fixed onto the two frames by using two pieces of alluminium bars with an L shape, drilled in order to fix them with two rivets to the frames:
    [​IMG]
     
  8. D-Mon Taurus

    D-Mon Taurus What's a Dremel?

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    Love the paint job, How big is that statue going to be..
     
  9. Rankine

    Rankine What's a Dremel?

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    Thanks! i had that painting idea just in time, because until to 5 minutes before start to paint I was determined to do everything glossy black.

    This technique has made the exact effect i wanted! :thumb:
     
  10. Rankine

    Rankine What's a Dremel?

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    hey guys, i'm so sorry for my absence but i had a terrible car accident and i had to stay far from my pc for a long time....

    i'll update the worklog soon! stay tuned!
     
  11. Shael

    Shael What's a Dremel?

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    Nice design i really like it :D :thumb:
     
  12. Rai

    Rai What's a Dremel?

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    Sorry to hear that. Keep up the good work on the mod.

    Perhaps the time of your post (at least according to my view): Today @ 13:37 is a good omen. :lol:
     
  13. Rankine

    Rankine What's a Dremel?

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    Let's start with the realization of the waterblock plate. I used an Ybris a.c.s. black pearl chrome waterblock, originally provided with a plexy plate for socket 775. But the motherboard uses socket 1156.....

    I started drawing the shape of the original plate on an alluminum 3mm plate, displacing the holes with a distance adequate for the 1156 socket. Then, I started to drill the plate:
    [​IMG]

    Her you can see the work in progress to obtain the hole for the waterblock:
    [​IMG]

    Mounting test:
    [​IMG]

    And this is the final result, compared with the orginal plate on the left:
    [​IMG]

    [​IMG]
     
  14. Rankine

    Rankine What's a Dremel?

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    Radiator lift mechanism develop.

    I wanted to put the radiator on the upper side of the mod, creating a system with a spring piston which allows the moving of the radiator-fan group: in this way, i have an easy access to the hardware.

    Unfortunately, i don't have photos of the realization, because i made them during working..

    Alluminum radiator support:
    [​IMG]

    System mounted:
    [​IMG]

    [​IMG]
    (Plastic bushings were then replaced with a steel cage ball bearings skf)
    [​IMG]

    Global work done:
    [​IMG]
     
  15. Rankine

    Rankine What's a Dremel?

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    Proceeding then with the part above the radiator, I originally used 3 black Enermax TB Silence fans (replaced later with Xigmatek bluelighted fan) and I wanted to make a little bit particular conveyor.

    First of all, i obtained from a 3mm alluminum plate a 120X360mm rectangle, after that i sawed the 3 circular holes for the fans:
    [​IMG]

    I then cut from a sheet of lexan, 9 half moons....:
    [​IMG]

    I grooved with Dremel the holes in order to fix the pieces of lexan and I glued them on the plate:
    [​IMG]

    Some tests:
    [​IMG]

    [​IMG]

    (In this picture you can see the stand at the start of construction):
    [​IMG]

    Final result:
    [​IMG]
     
  16. Rankine

    Rankine What's a Dremel?

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    Other pics:
    [​IMG]

    ON the back side of the motherboard support i fixed the EK bay trap:
    [​IMG]

    [​IMG]
     
  17. Rankine

    Rankine What's a Dremel?

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    Now, from the motherboard i wanted to move all the connection (USB, VGA, etc..) on the back side of the stand, then i wanted to realize something which permits to contain all the cables: therefore, i cut 8 alluminum vertebre, i drilled, polished and distanced each others with a series of pieces of transparent pvc tube. All is mounted as a sandwich (plate,distancers, plate distancers, etc...) through two stainless steel cables fixed under the stand:
    [​IMG]

    [​IMG]

    This is the final result:
    [​IMG]

    Ialso realized a front panel cover with a stainless steel inox plate, and i practiced four holes on it: these holes will host the rheobus for the radiator fans:

    [​IMG]
     
  18. Rankine

    Rankine What's a Dremel?

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    Worklog almost completed (the stand was not still completed):
    [​IMG]

    [​IMG]

    [​IMG]

    And here it is the version 1.0 of the finished worklog (i don't have pics of the inner side of the stand, because i had to finish it quickly for a contest here in Italy) :

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
    awadon likes this.
  19. bruce_rob

    bruce_rob What's a Dremel?

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    Nice build mate i like the way you have mounted the rad, very unique design hats off toy you
     
  20. Rankine

    Rankine What's a Dremel?

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    Thanks a lot bruce_rob, i'm so happy to hear this! :)
     

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