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Case Mod - Complete Boosted by Duality92

Discussion in 'Project Logs' started by Duality92, 7 Jan 2021.

  1. Duality92

    Duality92 What's a Dremel?

    25 Feb 2015
    Likes Received:
    --- Introduction ---

    Hey everyone! The name of this mod mod is "Boosted". Why boosted? Let me just explain this first and say how to mod was born.

    YouTuber "Major Hardware" is having a sort of fan showdown on his YouTube page where users can submit a fan blade design that he then puts on a Noctua fan hub and he rates them that way, this got me and my engineering mind to work, days past, weeks, suddenly I went to my parts bin in my shop to look for a specific fan and voila! Behold a 92mm, 38mm thick, 6000 RPM server fan from an Alienware Aurora R4 case! With that fan in hand, I could now start designing my idea.

    My idea was to create a sort of electric turbo, have it functional and supplying the whole system with cooling with it. At first I thought about having it supply air for the GPU and CPU via ducts to their heatsinks, but that quickly escaladed to what I'll be showing you today.

    Designing the fan was a fun learning experience for me as I work in SolidWorks, I never drew such a complicated parts with functions I normally do not use. So I knew I had to design it in three parts (ended up being 4, more on that later). I needed the turbo housing to be split in half to accommodate the turbo, so I ended up with the top housing, bottom housing and turbine.

    After designing I quickly realized I was at the limit of my 3D printer, so I had to shorten out the exhaust tube to make it fit along with re-adjusting the initial mounting hole locations, this brought me to four parts for the turbo itself.

    Then I started modding a Corsair 900D by removing the 5.25" bays, then making a cutout for the turbo itself with car intake performance cone filter, like you see on some turbo'd cars. For mounting the turbo, I simply used a sort of mounting cube made from 1515 aluminium t-slot from Spotswoods which made it super simple to mount. I then wanted to make this case more 2020 and the scratched-by-looking-at-it acrylic side panel didn't cut it. After looking through my stock on cases, I found that the InWin 509 window side panel fits really, really well on the case, oddly close. I then modded the InWin 509 glass mounts, which are screws on the 509 to fit the Corsair 900D to create the first real tinted tempered glass side panel in the world (that I'm aware?). I then took the old acrylic panel and will be using it to clean all the passthroughs and empty area where the 5.25" bays used to be (thinking green!)

    This done it was time to move on to the next step, installing some hardware to keep planning and modding the next steps. I installed the motherboard (Gigabyte C621 Aorus Xtreme), two bottom radiators (EKWB Classic PE 360 and SE 360), radiator/pump (EKWB Kinetic FTL 240), PSUs (two Seasonic Prime 1300W Platinums with CableMod Pro ModMesh cables), then my next hurdle was to figure out how I would take the air intake from the turbo and send it to the radiators, this is when I put my design skills to the test once again, I designed an intake manifold with one 2" entrace and eight 1-1/4" exits to fit right between both

    --- To-do list, also a sort of mod list ---
    • [DONE] Add pictures to this thread.
    • [DONE] Design flange to bolt on the manifold
    • [DONE] Cut up the manifold for 3D printing
    • [DONE] 3D print manifold
    • [DONE] 3D print flange
    • [DONE] Get 2" tubing for the plumbing (car exhaust tubing likely)
    • [DONE] Cut mid plate for cable/tubing passthrough
    • [DONE]Cut acrylic to finish the mid-wall
    • [DONE] Voltage gauges
    • [DONE] Temperature gauges
    • [DONE] Paint radiator fins to silver to look like intercoolers (both)
    • [DONE] Tachometers for pump RPM and turbo RPM
    • [DONE] Add LEDs in the case to see everything when the glass is on
    • [DONE] Add addressable LEDs in specific areas to create "under glow" type lighting
    • [DONE] Disassemble everything in the case to respray black everywhere from all the cuts, break clean up any cuts that are still "raw"
    • [DONE] Reassemble everything
    • [DONE] Vinyl decals
    • [DONE] Plumb EKWB watercooling
    • [DONE] Mod Hot Wheels Ford Transit SuperVan to fit theme (was the Gulf racing model)
    --- Completed hardware list ---
    • CPU : Xeon Gold 5218 ES (16c/32t) with EKWB Velocity WS
    • Motherboard : Gigabyte C621 Aorus Xtreme
    • RAM : Team Group 6*8GB Grey Vulkan Z
    • GPU : NVidia GTX 780 FE with EKWB FC
    • SSD : HP EX900 256GB with PCIE adapter
    • PSUs : Dual Seasonic Prime 1300W Platinum with Custom CableMod ModMesh Pro cables
    • Case : Corsair 900D with InWin 509 parts
    • Cooling : EKWB Classic PE 360 and SE 360, EKWB Kinetic FTL D5 240
    --- Updates ---
    1. October 30th, 2020 - Intro photo dump, fan turned into turbo, cutting opening for turbo, modding tempered glass from InWin 509, starting mid-wall plate with 900D acrylic window and manifold concept.
    2. October 31st, 2020 - Dual PSU with CableMod cables.
    3. November 5th, 2020 - 3D preview of the turbo setup.
    4. November 10th, 2020 - Design flange to bolt on the manifold, cut up the manifold for 3D printing, cut mid plate for cable/tubing passthrough, paint radiator fins to silver to look like intercoolers (both), disassemble everything in the case to respray black everywhere from all the cuts, break burrs and clean up any cuts that are still "raw", reassembled everything and installed TeamGroup RAM.
    5. November 12th, 2020 - Got my tubing for the turbo to the intake manifold (2" exhaust tubing), did some vinyl work, redid the mounting for the front panel to reflect theme and added tie-wrap decoration "à la" cheap drift car bumper fix, started printing the intake manifold (six total pieces for the manifold itself, one for the flange and a last one for turbo out extension)
    6. November 15th, 2020 - So I started working on making the tubing nice so I can clear coat it, finished 3D printing manifold and gluing and finished 3D printing flange and turbo extension tube
    7. November 18th, 2020 - Finished "brushing" the 2" exhaust tubing to use, added three main voltage displays on the frosted cover.
    8. November 25th, 2020 - So I put some white LEDs behind the custom frosted Modders-Inc logo, added three red LED Phobya temperature gauges, added silicone couplings, added the @moddersinc tag on the glass and added orange vinyl to two VRM fins.
    9. December 1st, 2020 - Soldered GPU 12V white LEDs for the waterblock, took some car wire harness tape to fit the theme and manage some cables and did the GPU power cable
    10. December 3rd, 2020 - Redid the mid-wall vinyl and cutting a smaller piece of plexi to cover the empty spot on the top left
    11. December 9th, 2020 - ARGB Cone filter and PC fan tachometers.
    12. December 16th, 2020 - Powder coated charge pipe, EKWB plumbing
    13. December 20th, 2020 - Last picture before photoshoot!
    14. December 22nd, 2020 - Final shots in case I don't get the AEM stuff in time!

    --- A Special thank you to my Sponsors ---
    TeamGroup with Three Grey Vulkan Z 2666 MHz 16GB (2*8GB) kits
    Seasonic with a Prime 1300W Platinum
    EKWB with watercooling gear
    AEM Intakes with a cone filter and intake for my car!

    Cheapskate likes this.
  2. Cheapskate

    Cheapskate Insane? or just stupid?

    13 May 2007
    Likes Received:
    NEAT! :rock: It's hella loud, isn't it? :lol: It's an interesting concept. It kinda takes a step back to when everything used a big monster blower, (Oh, man I wish I still had that '70s 10" Xerox fan.)

    You don't look at it with the appropriate amount of love and affection. :lol:

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