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Scratch Build – Complete Black Silence - passively cooled home theatre PC (COMPLETED+Final Pics)

Discussion in 'Project Logs' started by Bennibo, 27 Dec 2016.

  1. Bennibo

    Bennibo Member

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    Hi everyone,

    im new to this forum, actually this is my first post. Im Benjamin from Germany and i would like to show you my latest work.
    I finished this project a while ago, but since the new one im planning right now is based on a few aspects of this project, i thought i show you this one first. I hope thats ok.

    My plan for this project was to build a silent, passively cooled home theatre PC for my living room.
    Ive had the components before i started this. First i used a Akasa Euler with an external Bluray drive, but that didnt work out as planned since the BD drive refused to work most of the time. Then i got a MS-Tech MC-80 with room for an internal BD drive, which worked just fine, just wasnt completely silent. So i figured i had to build my own case.

    The components used for this are:
    - DQ77KB Thin Mini ITX Mainboard
    - Intel 3220T
    - 8GB Ram
    - 128GB MSata SSD
    - Slot in BR drive

    At first i planned everything in CAD:
    [​IMG]

    [​IMG]

    a view inside
    [​IMG]

    the frame
    [​IMG]

    a detailed view of the heatsinks
    [​IMG]

    i used aluminum tubing and connectors by Alfer for the frame.
    [​IMG]

    the heatsinks are 160x50x40mm in size
    [​IMG]

    then i bend aluminum for the front part of the case.
    [​IMG]
     
    Last edited: 28 Dec 2016
  2. Bennibo

    Bennibo Member

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    next i worked on the cooling system.
    i used copper for the CPU block and milled the cutout for the heatpipes into the heatsinks.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  3. Bennibo

    Bennibo Member

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    does a moderator need to approve what im writing every time, or is it just because im new?
    edit: it seems like no one had to approve my post this time, it worked right away.

    next i made these aluminum parts, which will be used to clamp the heatpipes
    [​IMG]

    i cut a bunch of threads into the heatsinks, so that i will be flexible with clamping the heatpipes. i rather be safe than sorry...
    [​IMG]

    also i cut the aluminum parts in shorter, more convenient sections
    [​IMG]

    a short test if everything fits. it does :)
    [​IMG]

    also i started working on the lid. first i used a plate shear to cut a piece of aluminum, then used a hacksaw and files to get the shape i wanted
    [​IMG]

    next was to cut a piece a acrylic for the lighting of the case with a jigsaw. of course i had to try how it looks with a flashlight.
    [​IMG]
     
    Last edited: 30 Dec 2016
  4. amagriva

    amagriva Member

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    Mhhhhh...Scratch built and silent...Juicy!
    Deffo subbed!:rock:
     
  5. LennyRhys

    LennyRhys Oink!

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    Welcome to Bit Tech! This is very cool - especially the custom built heatpipe cooling! :thumb:
     
  6. Nexxo

    Nexxo * Prefab Sprout – The King of Rock 'n' Roll

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    That's freaky... I am (very slowly) working on something similar:

    [​IMG]

    [​IMG]

    I think your design is excellent. Passive cooling really is the only way to go with a HTPC. While I'm here, may I point you to a suitably dinky PSU solution?

    Sorry for crashing your thread... carry on!
     
    Last edited: 31 Dec 2016
  7. Bennibo

    Bennibo Member

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    Happy new year everyone!

    thanks amagriva and LennyRhys :)

    thanks. thats ok, but im all set with the hardware for this build. im using a dell power brick from an old notebook. ;)


    next i had to do a lot of filing, until the acrylic had the same shape as the aluminum. also i cut out the middle part.
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  8. storm-83

    storm-83 Member

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    This is very interesting, and looks very cool (pun...) :thumb:
     
  9. Nealieboyee

    Nealieboyee Packaging Master!

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    [​IMG]

    I love scratch builds, HTPCs, and hand tools! Great start man! Keep it coming.
     
  10. Bennibo

    Bennibo Member

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    thanks guys! :)

    next, i worked on the buttom part. so again, first getting the aluminum in shape of the bend front part, then working on the acrylic.
    [​IMG]

    also cut out a piece for the back
    [​IMG]

    and of course another try with the flashlight. looking good so far. :D
    [​IMG]
     
  11. Bennibo

    Bennibo Member

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    it was time to finish the back. the cutout was made with a hacksaw and files.
    [​IMG]

    next i worked on the inside. the mainboard is mounted via standoffs the the case,
    [​IMG]

    the bluray drive still fits underneath the mainboard.
    [​IMG]

    then i started working on the mounts for the CPU-cooler. again with a hacksaw and files.
    [​IMG]

    not done yet, but getting there.
    [​IMG]
     
  12. Dr. Coin

    Dr. Coin Active Member

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    Looking very nice.
    Are your heat pipes pre-bent or are you custom bending them?
     
  13. Bennibo

    Bennibo Member

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    They came straight and bend them myself.
    i made a helper which worked great.

    [​IMG]

    [​IMG]
     
  14. Bartacus

    Bartacus Member

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    Very interesting project, nice work!
     
  15. Bennibo

    Bennibo Member

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    thanks :)

    next, i finished the mounts for the CPU-cooler.
    [​IMG]

    [​IMG]

    also i worked on the front. i wanted to have USB-ports in front, but i didnt want any screws visible. so i made a plate which hold the USB-header and is attached to the main frame. once again, i only used handtools for this.
    [​IMG]

    [​IMG]

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    after that i made the cutouts for the USB-ports and the optical drive in the front.
    [​IMG]
     
  16. Cheapskate

    Cheapskate Insane? or just stupid?

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    Awesome.:D
    Please post you heat pipe source. Google is flooded with stock coolers last I checked.
     
  17. Bennibo

    Bennibo Member

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    thanks :)
    i got the heatpipes at conrad.de. Im not to sure where to get them outside of Germany.

    next thing was to work on the power button. i didnt want it in the front, so i put it in the back, where it just fit.
    [​IMG]

    [​IMG]

    also i experimented with the finish. in this picture i sandblasted the front. it looks very smooth and clean.
    [​IMG]
     
    Cheapskate likes this.
  18. cobalt6700

    cobalt6700 Active Member

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    Nice work dude :thumb:
     
  19. neilhart

    neilhart New Member

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    Very nice project. Have you evaluated if the Intel HD 2500 Graphics suit your needs and the cooling of the 35 W CPU has any margin? You may want to switch to a i3-3225 CPU, 55 W, but has Intel HD 4000 Graphics which should provide better video performance.

    Just a thought. Again I have enjoyed your log with all of the great photos.

    Neil
     
  20. Nexxo

    Nexxo * Prefab Sprout – The King of Rock 'n' Roll

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    Here you go. UK based, but free international shipping. :)
     

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