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Case Mod - In Progress Morphosis - Cooler Master World Series 2019

Discussion in 'Project Logs' started by greensabbath, 24 Sep 2019.

  1. Jeff Hine

    Jeff Hine Nothing special

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    I'm anti-"Unicorn Vomit", too...
     
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  2. greensabbath

    greensabbath Got Wood?

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    Next I wanted to make a wood accent piece that mimics the design of the case window and acts as a partition in the case. I modified the same file I used on the window to make it deeper and cut a test panel. I then mocked up the test panel in the case:



    [​IMG]_9252882 by greensabbath911, on Flickr



    [​IMG]_9242880 by greensabbath911, on Flickr



    I then milled some Walnut to the approximate size I needed. I paid special attention to the grain to ensure it would look cohesive.



    Here are the two pieces:

    [​IMG]_9252883 by greensabbath911, on Flickr



    Even without glue it is hard to see where each piece ends:

    [​IMG]_9252884 by greensabbath911, on Flickr



    After it was glued, I milled it to a bit over 1/2 inch thick and set it up on the wasteboard and got to cutting:

    [​IMG]_9262895 by greensabbath911, on Flickr



    [​IMG]_9262909 by greensabbath911, on Flickr



    All done but before sanding:

    [​IMG]_9262913 by greensabbath911, on Flickr



    All sanded and ready for finish:

    [​IMG]_9262916 by greensabbath911, on Flickr
     
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  3. greensabbath

    greensabbath Got Wood?

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    I finished the feet with a few coats of General FInishes Arm-R-Seal and now they are ready to mount to the bottom of the case:

    [​IMG]_9292949 by greensabbath911, on Flickr



    [​IMG]_9292950 by greensabbath911, on Flickr



    Checking the fitment to make sure the reveals are even:

    [​IMG]_9292952 by greensabbath911, on Flickr



    [​IMG]_9292953 by greensabbath911, on Flickr



    [​IMG]_9292955 by greensabbath911, on Flickr



    [​IMG]_9292956 by greensabbath911, on Flickr



    I fastened the case feet with four screws into each one. The feet have chamfers to help connect the lines of the case.



    Next, I turned my attention to the power supply shroud. I like the system that the case uses so I'm going to modify that.

    [​IMG]_9272921 by greensabbath911, on Flickr



    I have a bit of veneer aluminum still so I'm going to attach some of that to the shroud and blend it into the rest of the case:

    [​IMG]_9272918 by greensabbath911, on Flickr



    I wanted to make sure I had a nice mitered joint so I used some scrap wood to get the angles right:

    [​IMG]_9272922 by greensabbath911, on Flickr



    First piece cut, just making sure the fit is right:

    [​IMG]_9272924 by greensabbath911, on Flickr



    I cut the pieces close together to ensure the grain would carry over from one piece to the other:

    [​IMG]_9272929 by greensabbath911, on Flickr



    [​IMG]_9272930 by greensabbath911, on Flickr



    [​IMG]_9272931 by greensabbath911, on Flickr



    I also sanded the edges to give them a brushed look:

    [​IMG]_9272926 by greensabbath911, on Flickr



    With the panels attached to the shroud, I could mock it up with the Walnut panel I made last time. It has a couple coats of finish but is not entirely done yet:

    [​IMG]_9272935 by greensabbath911, on Flickr



    [​IMG]_9272936 by greensabbath911, on Flickr
     
  4. greensabbath

    greensabbath Got Wood?

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    One of the last tasks before I could finally start putting the case together the final time was making the attachment points for the two window panels. Two of these I have previously made but the other two needed to be done using the existing structure of the case. In each corner is a little corner bracket made of steel but it is too thin to put threads in so I wanted to remake it out of aluminum.



    The piece to be made:

    [​IMG]_9272938 by greensabbath911, on Flickr



    I modeled it in Fusion 360 and cut out four of them at the same time:

    [​IMG]_9292941 by greensabbath911, on Flickr



    [​IMG]_9292942 by greensabbath911, on Flickr



    I drilled the screw holes and then made the counter sinks to match the case panels:

    [​IMG]_9292960 by greensabbath911, on Flickr



    [​IMG]_9292963 by greensabbath911, on Flickr



    I threaded the holes and they were good to go:

    [​IMG]_9292964 by greensabbath911, on Flickr
     
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  5. Cheapskate

    Cheapskate Insane? or just stupid?

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    You managed to use tape on such a tiny part? Your bit/router setup must manage the heat buildup well... or something.
    The case is approaching maximum lovely. To get any more lovely involves going full scratch build.
     
  6. greensabbath

    greensabbath Got Wood?

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    @Cheapskate Ive been using a single flute 3/16 endmill taking between .3 and .4mm per pass with 900 mm/min cut speed... and I used a crapload of glue. The little shavings are pretty warm but the piece itself usually isn’t too bad. Thanks for the compliment, I’d really wanted to do a scratch build (I’m more comfortable with those) but the allure of the 10k top prize for case mods was too hard to pass up.
     
  7. Cheapskate

    Cheapskate Insane? or just stupid?

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    :lol: That's 5 times my preferred cut speed. As I suspected, my cheap general-purpose bits are probably to blame. Big shock.
    [crapload of glue] : It was the tape stickum that was failing for me. Small parts would move as they were cut. I switched to window glazing caulk on MDF. You have to soak the finished cut in water to break up the mdf it holds so well.
     
  8. greensabbath

    greensabbath Got Wood?

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    I see most people using blue masking tape but I used the regular stuff since it was so much cheaper. It also seems like it’s stickier? The weak link is the connection between the tape and the mdf wasteboard though.

    I tried cutting aluminum with some end mills I already had (before getting the single flute) and the results were pretty horrific for me. I also use a single flute with the acrylic.
     
  9. greensabbath

    greensabbath Got Wood?

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    With the corner brackets made, I could drill holes in the windows for the bolts. I taped the acrylic window to the aluminum piece underneath ti ensure the holes would line up:

    [​IMG]_9292972 by greensabbath911, on Flickr



    [​IMG]_9292970 by greensabbath911, on Flickr



    [​IMG]_9292982 by greensabbath911, on Flickr



    I then drilled holes into each support piece and tapped threads into each piece.



    The second window is going to be made out of 3/16 inch aluminum. I wanted a brushed finish to match the rest of the case so I needed to use my drumsander again to achieve this.



    Before:

    [​IMG]_9262915 by greensabbath911, on Flickr



    After:

    [​IMG]_9292940 by greensabbath911, on Flickr



    More on this piece later.
     
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  10. greensabbath

    greensabbath Got Wood?

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    I was not originally going to use mesh over the fan grills but I decided to try it out and see how it would look:

    [​IMG]IMG_6602 by greensabbath911, on Flickr



    This is A.C. Ryan silver mesh. It is steel so it was not very easy to cut. I'm glad I tried this though because I think it turned out great. It really makes the grill design pop:

    [​IMG]IMG_6603 by greensabbath911, on Flickr



    [​IMG]IMG_6606 by greensabbath911, on Flickr



    I put it over the top grill too:

    [​IMG]IMG_6608 by greensabbath911, on Flickr



    I also installed the LED strip into the top, making it ready to be put into the case:

    [​IMG]IMG_6610 by greensabbath911, on Flickr

    [​IMG]IMG_6611 by greensabbath911, on Flickr



    [​IMG]_A020021 by greensabbath911, on Flickr



    Next, I wanted to make covers for the holes around the motherboard to help with cable management. I had some veneered aluminum still so I cut some of that to make a board around the motherboard. I can then mill these pieces to fit the cable design later:



    I started with the mitered corner:

    [​IMG]IMG_6596 by greensabbath911, on Flickr



    And I cut the rest to fit from there:

    [​IMG]IMG_6598 by greensabbath911, on Flickr



    [​IMG]_9300004 by greensabbath911, on Flickr



    They are in sections so I can mill some of them without having to take it all apart. They screw into the motherboard tray and cover holes behind them which will also be used for cable management.



    I made one for the CPU power hole too:

    [​IMG]IMG_6601 by greensabbath911, on Flickr



    The power supply mount is also getting an upgrade. I'm doubling up the support bracket so I can mount a cover on top of that:

    [​IMG]IMG_6600 by greensabbath911, on Flickr



    The cover piece will look something like this and get bolted on:

    [​IMG]IMG_6597 by greensabbath911, on Flickr



    [​IMG]_9300013 by greensabbath911, on Flickr



    I wanted to finish of the cover pieces to match the rest of the case so I brushed the edges of the aluminum and gave them a chamfer:

    [​IMG]_A030057 by greensabbath911, on Flickr



    [​IMG]_A030047 by greensabbath911, on Flickr
     
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  11. Cheapskate

    Cheapskate Insane? or just stupid?

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    I think the best part is knowing you won't defile it with a dozen logos for the finale. I can enjoy the aesthetics without fear of it turning into a race car.
     
  12. greensabbath

    greensabbath Got Wood?

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    I appreciate that. I actually kind of forgot to put one in... I was going to do a Cooler Master logo somewhere (that I could take off after photos) but in the craziness of trying to finish, i forgot about it. Hopefully that doesn't hurt me too much.
     
  13. Cheapskate

    Cheapskate Insane? or just stupid?

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    The days when 'good' would win you contests are over. Large foreign modding groups and facebook campaigns get the wins a lot now.
     
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  14. kim

    kim hardware addict

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    Perfect combination between wood and steel, (I love that combo personally), great modding skills too:dremel:, a pleasure to follow your thread...and...certainly one of the most beautiful case mod I saw this year :thumb:
     
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  15. greensabbath

    greensabbath Got Wood?

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    I think that turned me off from modding for a while. Even though I had a decent shop, its hard to compete with people with money, CNC machines and lots of sponsorships. Makes me wonder how my previous cases would do in the current contests.

    Thank you! I appreciate the compliments.
     

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