Scratch Build – In Progress Completed: Aelro Dynamic: 05-15-2010. Temperature's! Does Channel Air-Flow Work??!!

Update: Top Case Cover and Base

Jus got home from work and fabrication. I can luckily do both at the same place, thanks to working at an awesome family company that lets me in my spare time.

Today I started, what really is to me, Phase 2 of the project. Which is the whole Top Case cover. Hope you all enjoy. I found my addiction in life.


So this is the top of underbody of the case. I putting a piece of Plexiglass inbetween the bottom and top bases and luminating the plexiglass. I still havent order'd the plexi yet, cuz I still deciding over color or jus clear. The nuts are there to simulate spacing.



Got it traced out! Started cutting. Jus used old template from bottom. Reason. Has to match top, making a new template may cause differentiation in measurements



Almost there!



All done! What mess the AL dusts makes, lol



Now time 2 cut those wing looking things. One for the left and right





There is the Top Case Cover base electrical taped on.



To show you all, what the spacing looks like!



Start of Top Case Cover!

Start by mocking up with the side. These I know I have down in measurement on the cardboard and dont have to check.



Cutting Out!





Side Note: I realized today that my camera did not save all the pictures I took Reason for some jumpness here in pics.

Got to figure out the front cover, cause this cardboard isnt matching up to my dimensions.



Figured it out and got it cut out!



Slappin it all together now.



From the side



Just a sneek peak of whats next...kinda of.



Updates Daily!

 

wow i really loke this mod it looks like you are building a space ship or something really cool

 

Good work !
Very cool, looking great so far. Keep going, I wanna see it finished!
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When do the wheels go on?

 

wheels?

this thing looks like it takes jet engines! very nice work, cant wait to see what it looks like when its all been welded.

 

Talking about welding!!! Lets not go there, lol, Heat n AL do not go well at times, my welder who is my cuzin is goin 2 have 2 summon his very best.

 

Update: Top Case Cover Crown!

Daily Update! Finishing off from yesterday, the Top Case Cover Crown.

Start by grabbing sum scrap AL lyin around. Looks like it will work. Mark it and cut it.



The Result



Grab another piece of scrap Al and grab the ruler while I was at it. Got to measure this one up.



Measuring to the MM!



Cut it and taped it.



Lookin good so far



From inside looking up



From the back with all that space for my mobo.



Talkin abt the back...to finish the crown I have to build the rear of the crown.
.


I cut my side piece, in the lower right of the photo, F'in camera still actin up. Than "Oh ****" happened. Had to go back to the design board to redo this cardboard piece. Now this was going to redo my design in the back now, by a slight bit, stay tuned you'll see.



Pulled out the Ruler and did some quick measurements, Tracing, n cut and this is the result



My Video Card cardboard mock-up. The tolerances are real tight in this case for everthing.





Got the other side Traced up and Cut out.



The result



Different Angle



The Center of the All the pieces meet quite nice. Not exactly to precise and for the weld, lets not go there on this area, cuz I cringe



Last piece for today. This empty triangular area.



Got the pattern. Time to trace and cut.



And Waalllaaahhh



Another Angle, All together.



That is for Today! Tomorrow I work on the back of the Top Case Cover.

 

Dude, I love how this thing looks Want to see it finished

 

Looks awesome.

BUT:
Where are you gonna hide the flamethrower? I bet that would be sick at a lan

 

Update: Top Case Cover: Back

Update: Where did the heck did I leave off...! Jus been such a busy week, didn't do an update yesterday, so today it is a big one. Enjoy.

So I finished the Crown the other day and now I am moving onto the lower back portion of the Top Case Cover. I started off, by doing the middle section below and will work out from there. While it was good to start here it is also bad. You'll see later.



Once I got the middle-cut out and taped up I started to work on the side next to the middle. As you can see the one side already cut out and standing next to the case.



Taped up'd, looks good so far.



Time for the other side. Got the ruler out, did some measuring and traced. kinda of hard to see here.



Cut Out



Taped up'd. Not 2 bad. Wish it was laser cut! Where is that kids home-made laser cutter, lol.



From the top



Now I got to do the sides. That big gaping hole there.



I love Paper



Mountin that sucker in there.



Oh "insert curse word"!A: Throw tools across room B: Yell, insane profane language till catholic churchs calls C: Repeat Step A thru B. Sometimes you dont get it right. See that gaping hole there.



After taking a break. I remeasured and cut! The result



We got a winnner.



lookin in and up.



Time for the other side.



Measured, Traced and Cut



The fit



Onto this piece, now! Where the hole is.



Recut measure and cut and few hours later, this is what I got. Little uneven, nothing a file cant handle.



After the file hit it. The bottom edge looks even.



Time for the Corners there. Did some simple trace and cut with scrap pieces of AL to get this result



Other side



Whhhooohhh! Last section to do.



This is how I started off.



Did the other side the same way and measured out for my top plate there. Dumb Camera didnt save sum pics again



Finally, All Done. The Result



Different Angle



The Top Case Cover Complete, still got some stuff left to do.



From the back



Well, the basic frame of the case is complete. Top and Bottom. Time to move onto weld and fine tune of all the metal and other work. Stay Tuned.

 

Now get that stuff joined up!

 

Quick question))) Is the case is going to be welded together, then how would you put all of your hardware in (not considering the fact that if something would go wrong with your hardware(HDD getting messed up or something...))

 

That is the whole next phase of the project. Which is putting in all the bracketing and holes required for Aelro to become a functional computer case. That is a good question to ask to, cuz sum ppl were probably wondering the same thing. Stay tuned and you'll see, how I try to get this all done. The tolerances in this case are tight though, cuz it is suppose to be mATX case.

 

I thought some points in my fabrication were going to be tough, this whole weldin deal with this AL is giving me alot of stress. Jus dreading it, it will get done. It will also take about a month to do!

 

looking good, Had the same question a RuSGaMeR... can't wait to see how you do this...Will be eagerly waiting.....

 

Update: Front Air Intake's

Part of my weekend update is fabricating the Front Air Intakes for the case. I wanted to do a general mock-up first of the case, before I moved onto some of the finer points of the machine. To me doing everything at once can be bad.

So lets revisit for a sec. Those flat face plates on the front have to be fabricated to let Air into the radiators.



I de-assembled the case, or "cough" "cough" it fell apart the other day. Had to take it apart anyway, so here are the flat face plates that need modification. I traced a design in, now to go cut...



There we go, cut out and taped up for more measurements and design work.



Aaahh, Paper, got luv it! Once again it is coming in handy for me.



All the pieces needed for the Intake cut-out. now jus assemble



Assembled!



View from the front



Attached to the case



Another View



I put everything together for the front face and this is what I have now.



Last view.



Hopefully, another update tomorrow.

 

It reminds me of Martha from A Town Called Eureka

Epic

 

Those look sweet!!!

 

Awsome work cant wait to see the finished product subbed

 

Looks awesome! Good work