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

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:




a view inside


the frame


a detailed view of the heatsinks


i used aluminum tubing and connectors by Alfer for the frame.


the heatsinks are 160x50x40mm in size


then i bend aluminum for the front part of the case.

 

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

 

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


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...


also i cut the aluminum parts in shorter, more convenient sections


a short test if everything fits. it does


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


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.

 

Mhhhhh...Scratch built and silent...Juicy!
Deffo subbed!

 

Welcome to Bit Tech! This is very cool - especially the custom built heatpipe cooling!

 

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





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!

 

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.

 

This is very interesting, and looks very cool (pun...)

 

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

 

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.


also cut out a piece for the back


and of course another try with the flashlight. looking good so far.

 

it was time to finish the back. the cutout was made with a hacksaw and files.


next i worked on the inside. the mainboard is mounted via standoffs the the case,


the bluray drive still fits underneath the mainboard.


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


not done yet, but getting there.

 

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

 

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

 

Very interesting project, nice work!

 

thanks

next, i finished the mounts for the CPU-cooler.




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.








after that i made the cutouts for the USB-ports and the optical drive in the front.

 

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

 

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.




also i experimented with the finish. in this picture i sandblasted the front. it looks very smooth and clean.

 

Nice work dude

 

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

 

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