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Scratch Build – In Progress Jestercon - Update #8 (Mar24th - Some Disasters and some progress)

Discussion in 'Project Logs' started by Blooddrunken, 5 Jul 2010.

  1. Blooddrunken

    Blooddrunken In Flames we Trust

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    Hi,
    I want to introduce you into my first build after a pause of 5 years.

    Inspiration
    The Inspiration for the theme is the Jesterhead of In Flames, as I'm a big fan on them. :rock:
    [​IMG]

    Design
    I started with the design a few months ago with the inner res.
    [​IMG]
    I first build the case around this res, but changed the design a few times.

    The color scheme will be in Black and Red High Gloss Plexiglass.
    [​IMG]
    [​IMG]

    The design for the front is a bit like the front of Cheaps build, but I found the front that nice that I thought I will copy it and change it a bit.

    The "hidden" inner will be nearly empty, just the necessary should be in:
    [​IMG]

    At the first stages of the Design I gone with the res, I showed above, as the borderline for bottom and front of the mainboard area. Later I changed it to the Jesterhead fins of the Front as a massive block.
    [​IMG]

    Start of Build
    Last week I begun with the building of the case.
    I first did the top of the case:
    [​IMG]

    Last weekend I started with the cutting of the Plexiglass for the Jesterhead fins of the bottom borderline for the mainboardarea:
    [​IMG]

    Today I finished the cutting of the Plexiglass and started with the first two fins.
    [​IMG]

    Afterwards I filed the bottomedges straight and glued them together.

    I will update this thread as often as I have something to show you.

    I hope you liked the beginning of this Project and thanks for watching.
     
    Last edited: 24 Mar 2011
  2. Cheapskate

    Cheapskate Insane? or just stupid?

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    :D Yes, I do like it. I gotta warn you - It's a lot of friggen work to do the fins!
    -Oh, and number them! As subtle as the change is in your fins, I would have trouble telling them apart for assembly. -You should be able to clamp them together and sand them, though.
     
  3. Blooddrunken

    Blooddrunken In Flames we Trust

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    Thanks Cheaps. :)
    Yes I know it will be a looooooot of work to do the fins and I'll have to see how I will do it best. The curves are all the same on all fins - they're just a bit shorter every fin, so maybe I use dual sided tabe to glue them together and sand them then.
     
  4. Delta Nine IT

    Delta Nine IT New to this but not to Modding!

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    Good luck with this, looks like a lot of work!
     
  5. Blooddrunken

    Blooddrunken In Flames we Trust

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    Update #1

    Thanks - Yes it's a lot of work, but while planning the case I looked for the things I liked and not was is less or more work. ;)

    The last few days I did a lot of work. :)

    More Details
    I added a few details to the Sketchup files on the left side of the Case.
    I will place a In Flames Shield of 2 3mm Plexiglass sheets. 1 Brown as the base plate which will be lighted from behind with LED's and a orange sheet on top of this.
    [​IMG]

    Inner Res
    The shape for the inner res was first drawn to the plexi sheet.
    The first step that needed to be done was to drill a few holes in it to be able to cut it which the jigsaw.
    [​IMG]
    Afterwards I cut it out.
    [​IMG]
    Filed and sanded it down (not finished with the grinding and polishing yet).
    [​IMG]

    Afterwards I drawn the middle point for the watercooling connector to the 5mm sheet which will be glued to the 10mm Plexisheet for the Res.
    [​IMG]
    I drilled the hole
    [​IMG]
    and cut the 1/4" thread into it.
    [​IMG]

    Here's a pic of the res layer laid to the connection layer.
    [​IMG]

    Right side
    Furthermore I did the mainwork on the right side sheet of the case.
    First I have drawn the lines for the cut.
    [​IMG]
    Then I cut the edges with a 50mm holesaw and cut the lines with a jigsaw.
    [​IMG]

    Backside
    On the backside sheet I cut the holes for the cooling.
    [​IMG]
    [​IMG]
    Here I messed up some of the holes. :/
    [​IMG]

    But I have already an idea how I can rescue the sheet and I think it will look even better.
    I will cut a bigger hole into the backsheet and will cut 2 pieces out of other Plexisheets, will drill the holes into these and will light 'em up with LED's.
    [​IMG]
    The white pieces will be in the same material as the rest of the case, but there is only 1 side colored, so it's possible to light the plexi up and have the back in a non transperant black. (I will have a look if I find a tutorial for light and so on for Sketchup. Or does anyone has a good one?)

    Inner Fins
    Yesterday I cut the remaining inner fins out of the 10mm plexi sheets.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Today I glued them in many steps all together to get the 1 piece.
    First to 2 piece pieces.
    [​IMG]
    Then to 4 piece pieces, 8 piece pieces and so on and so on.
    [​IMG]
    [​IMG]

    Next steps will be the sanding of them to get a onepiece.


    Front Fins
    As I wrote in my reply this is the way I'll try to send the front fins to match each other.
    [​IMG]
    Here you can see that the end of them is smaller on every fin, but the front and the shape is allways the same.
    [​IMG]


    Thanks for watchting. Comments, critism and questions are allways welcome. ;)
     
  6. Blooddrunken

    Blooddrunken In Flames we Trust

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    Update #3 (Aug 28th)

    Hi all,
    It's been quite a while since my last update on this build, but I wasn't that lazy as it looks like. :D

    In the last month I worked quite much on the case.

    The first thing I did was to check how the case would look at the end, so I took some strong tape and taped outer pieces together.
    [​IMG]
    [​IMG]

    The next cuts were done on the front panel.
    Therefore I marked the cut outs for the fan holes...
    [​IMG]
    ...and cut them out.
    [​IMG]

    This is how it looked on the taped build:
    [​IMG]


    Afterwards I filed and grinded the edges of the fan holes in the front, the window in the top and the side panel and the into the exact size and to a nearly clear edge. (the last finishes will be done at the end.)

    In the next Step I glued the top, front and bottom plate together:
    [​IMG]
    [​IMG]


    I were the last week visiting my parents where I have a dremel and can use it (in my kitchen it's not that good to use it and do lots of grinding :blush:), so I did the In Flames "Shield" for the left side panel.
    First I did some print outs of the pieces, cut then out with a scissor and took the form to the 3mm plexi sheet.
    [​IMG]
    Did it for the red plexi too, but forget to take some pics and had forgotten my cam to take it with me to my parents, so I don't have pics from the progress of some work done.

    In the beginning of the last week I cut these parts out of the plexi and here you can see the result:
    [​IMG]
    (I know it's has not a 100% accuracy like oldnewby's build's, but I'm happy with it. ;))

    The next days I spend with the grinding of the jesterhead panel. This was a horrifing work, but it has be done, but there's a lot of work still to do.
    I first started with a 40 grind paper on the bottom to get a plain surface. After having a nearly plain surface I took some 80 and then 180 grind paper.
    [​IMG]

    Afterwards I started with the grinding of the top of this panel - the more horrorfying work. Here I started with the grinding tool on the dremel to get the coarse surface irregularities to a minimum. Afterwards I gone on with some 40 grind paper and am still stuck on it.
    [​IMG]
    [​IMG]
    My vacation is over, so I'm now back in my apartment and am not able to grind on it anymore. :waah: (but it's better for my hands. :D)

    At the beginning of this week the new panel (2nd) for the backplate arrived here, because I measured some wrong on the first one. I still worked with steel drilling bits and nearly every second hole cracked at the end of the drilling process. :wallbash: I could drill fast, slow, I tried nearly everthing and it didn't worked well, so I ordered this part a 3rd time and this time I additionally ordered some plexi drilling bits.
    Yesterday the parts arrived and I started working on the new backplate. First I marked all positions again and started drilling the first holes. (forgot to take a pic or two :wallbash:)
    [​IMG]

    Today I did the "last" holes on the backplate.
    [​IMG]
    Here you can see that the holes drilled with the plexi drill bits are much cleaner then the other ones:
    [​IMG]

    The next steps I'll do are: (mixed order)
    • drill the mounting holes for the power supply
    • cut the opening for the power supply
    • cut the hole for the bla
    • glue the backplate to the build
    • finish the mainboard mounting plate
    • glue the mainboard mounting plate to the build
    • complete the inner res
    • complete the jesterhead panel
    • glue the shield to the side panel

    Comments are welcome as always. Cheers
     
    Last edited: 28 Aug 2010
    Fiyero likes this.
  7. Anubus

    Anubus Minimodder

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    This build is going to be amazing when it is finished:thumb:
     
  8. Fiyero

    Fiyero Vindaloovian

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    Oooooohhhh! As soon as I saw Jester I was praying it was something to do with In Flames!!
    Subbed for sure :D
    And +rep for pure awesome.
     
  9. Blooddrunken

    Blooddrunken In Flames we Trust

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    Thank you - I'll give my best.

    Thanks man. :thumb:
     
  10. HoryBP

    HoryBP What's a Dremel?

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    Wohoo A lot of plexi. This will be awesome with LEDs
     
  11. Blooddrunken

    Blooddrunken In Flames we Trust

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    Update #3

    Welcome to my third update on the Jestercon scratch build in which I want to show you what I did the last week. :D

    Backplate
    Last weekend I started with the backplate of the build and cut the hole for the mainboard connectors and the power supply.

    I took the backside of an old mainboard tray from a chieftec dragon case. I overtook the meassurements to the plexiglas.
    [​IMG]
    [​IMG]

    Afterwards I drilled on the edges some 8mm holes for the jigsaw...
    [​IMG]
    ...and cut it out.
    [​IMG]

    I hold the backside of the mainboard tray on position and it looked good.
    [​IMG]

    Today I did the cutout for the power supply. Therefore I took some meassurements and marked them on the plexi.
    [​IMG]

    I drilled again some 8mm holes...
    [​IMG]

    ...cut it with the jigsaw...
    [​IMG]

    ... and filed the edges straight.
    [​IMG]

    Here's a sneak preview how shiny the plexi will be at the end. :rock:
    [​IMG]

    This piece was also the last of the 4 pieces for the outer frame and as it was finished I glued it to the other 3:
    [​IMG]


    Mainboardplate
    To have a cleaner view inside I decided to route the mainboard cables behind the mainboard through the plate.
    I marked 3 lines with 10mm width between them and marked 2 positions for the 20mm holes at the end:
    [​IMG]

    I first drilled 2 holes with an Forstner bit and cut the lines afterwards with the jigsaw:
    [​IMG]

    The edges weren't straight enough so I filed the straight. :eeek: :D
    [​IMG]

    The position will be in height of the gfx under the mainboard:
    [​IMG]

    Mainboard spacer
    On the above picture you can allready see 2 of the mainboard spacers the mainboard will be screwed on.
    I cut first a 10mm width bar from an 10mm thick plexiglas plate.
    [​IMG]
    [​IMG]

    Afterwards I cut them into 24mm long pieces.
    [​IMG]

    I need 9 of them for the mainboard.
    [​IMG]

    Afterwards I drilled a hole for the tap in...
    [​IMG]
    [​IMG]

    I tested the first one.
    [​IMG]

    Here are the 9 nearly finished:
    [​IMG]

    Mounted them to the mainboard:
    [​IMG]
    [​IMG]

    I checked if everything is fine and it looks good. :)
    [​IMG]

    The last thing I did were miter the edges:
    [​IMG]

    These were M4 and the M4 screws fit perfectly in the holes of the mainboard, but I think it cause problems while installing the mainboard so I created 9 new ones with M3 holes.
    [​IMG]

    Should I use the M3 or M4 ones? What would you prefer?

    Front Res
    Yesterday I started with the front res.
    First I glued 3 of 3mm thick 50mm diameter plexi pieces together for the bottom.
    Afterwards I marked 2 positions for the watercooling connectors:
    [​IMG]

    Drilled and taped some holes (11,2mm and G1/4"):
    [​IMG]

    Then I used 2 of previous templates for some mounting holes:
    [​IMG]
    [​IMG]

    Here you can see the 2nd version compared to the first version:
    [​IMG]
    (2nd left 1st right)

    The problem with the first one is that I think that the 2 holes for the watercooling connectors are too close together so I will not be able to screw the connectors fixed.

    The bottom plate on the 50mm diameter res:
    [​IMG]

    I allready glued the inner tube to the bottom.
    [​IMG]

    I made the top of the res too, but I don't know if I will redo it some day, because I think the tap isn't even. :/
    [​IMG]

    In Flames Shield
    Last weekend I glued the In Flames Shield to the left side.
    First I glued the red pieces...
    [​IMG]

    ... and after the glue was dry I glued the white pieces.
    [​IMG]

    I will not use the white piece in the name sign, because I think it looks better without it. Maybe I will make a name later on out of the white plexi and use it in the space.

    Front Fins
    This week I cut the first fin for the front out of the red plexi.
    Therefore I printed a template out and cut it later. This template was copied to the plexi.
    [​IMG]

    The next step was to drill a hole in the middle to be able to make the cuttings there.
    [​IMG]

    Then I did the first cuts:
    [​IMG]
    [​IMG]

    And viola:
    [​IMG]
    [​IMG]
    [​IMG]

    Inner "Fins"
    For the inner fins I needed 1 more fin with a thickness of 6mm, so I created one from the "black" plexi. As only 2 side of the plexi is black I can use it as endpiece which will be glued to the backside at the end.
    [​IMG]
    [​IMG]

    Today I wetsanded it a bit, but there is still a looooot of work to do. :rolleyes:
    [​IMG]


    I will try to do the updates more often and smaller then. ;)

    Comments and critism is welcome as always. Cheers. :thumb: :rock:
     
  12. Raiden

    Raiden Portuguese reviewer

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    Good job , keep on modding !!!:thumb:
     
  13. Blooddrunken

    Blooddrunken In Flames we Trust

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    Thank you very much. :)
     
  14. LooseNeutral

    LooseNeutral What's a Dremel?

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    Oh Yeah, I'm in! Looks great man. No modding for 5yrs?:eeek: And you're doing this! :rock:Awesome. SUB'D:D *Are you cutting this stuff yourself and how?
     
    Last edited: 29 Aug 2010
  15. Blooddrunken

    Blooddrunken In Flames we Trust

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    Thanks man. :thumb: Yeah I think in these 5 years I had only 2 times my drill in my hand. :D Not everything went well though as I wrote I had done the backpiece 3 times to be happy with. ;)

    The big sheets were cut at the vendor (http://www.plexiglas-shop.de (The shop of the manufactur Roehm/Evonik)), but I think next time I will do it on my own, as the cutting prices aren't that cheap and with their plexiglas cutting blades for the jigsaw the results are nearly as good as their. Actually I'm not watercooling or aircooling thejigsaw blade, but I think this would give me better results, but it's not that easy to do it on your own and not to ruin the complete kitchen. :D
     
  16. Blooddrunken

    Blooddrunken In Flames we Trust

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    Update #4

    Today I did a few small things.

    First I checked out how the case looks like at the moment:
    [​IMG]
    [​IMG]

    Then I took my M4 mainboard spacers to use them for another part. :D
    I'll take them for both sides of the case to be screwed to. Therefore I glued them into the corners like this one:
    [​IMG]

    The next mayor construction zone will be the fins of the front.
    I started with the res holding plate. Mark it on the tape on the plexi...
    [​IMG]

    ...mark the holes for the screws...
    [​IMG]

    ...and cut everything out and drill the holes.
    [​IMG]

    After that I did the first testfitting:
    [​IMG]

    After that I had to mark up the holes for the connectors:
    [​IMG]

    I took again my 20mm forstner drilling bit and filed the middle pieces even:
    [​IMG]
    [​IMG]

    On the lower part of the front will be some fullsize fins, so I did some on them:
    [​IMG]
    [​IMG]

    On the second I cut the middle part out, because this will take the place in front of the holes for the hose.

    I started doing some of the smaller fins in even steps 5mm, 10mm, 15mm:
    [​IMG]
    [​IMG]
    [​IMG]

    Have a nice sunday. :thumb:
     
  17. Cheapskate

    Cheapskate Insane? or just stupid?

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    Looking great so far.
    I think part of why you're having trouble getting the big layered bit sanded is how you are sanding it. You need a long block for the paper to get everything evened up. The hand sanding is sanding down the low spots too, so you will never get rid of them like that.
     
  18. LooseNeutral

    LooseNeutral What's a Dremel?

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    Nice update. Looking good. I don't envy all the sanding you've got to do. :D
     
  19. Blooddrunken

    Blooddrunken In Flames we Trust

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    Thanks Cheaps. Yeah you're right - I'll try it with a block.

    Thank you. :)
     
  20. Macros_the_Black

    Macros_the_Black Yup.. I'm a f-ing reptile

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    Nice project! Love the design! Hehe, the fact that you do everything by hand makes it even better... all those fins.. lots of work! I admire you patience. Can't wait to see more! (subscribed)
     

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