Case Mod - In Progress Project: 900D Monster Xtreme

Then I fixed the central structure over the 900D and between the 2 Cooling Towers using 25mm screws and nuts. I fixed the structure with clamps so that it was in correct position. I have marked the points where do the holes, drilled, passed the screws, initially thought to fix it down even to the 900D but it is not necessary.






And here is the result, notice how the parts are perfect on top




Remains the central part where are 4 140mm fans. I started always from a profiled of 2.5 cm x 200 cm, I cut to size using a Dremel to 55.6 cm and I did a placement test.





I fixed the 2 bars in place with clamps, I marked the drill holes so that the screws don't obstruct tthe later step and I screwed with 20mm screws







And here is the final effect



Disassembled the entire structure I returned to work on the central body more easily. In particular, I started working on the side supports for the 4 140mm fans. In the 900D here are 4 120mm fans so I must saw itaway and rebuild custom.
I used L 25X10 mm profiled , I cut to size (55.6 cm) using Dremel, a bit of file and now I try only the positioning.






With the fans between the two profiled the effect is that, the profiled have yet to be finished, but this is the next time!

 

Hi guys,

I worked on side fans groups of which I had done some test last time.

I started from the usual 4 fans support of Cooling Towers, I have fixed 2 fans on one side and on the other side I put the L profiled, putting it perfectly in place. I blocked it with clamps, drilled and drew the outline.
Then I sawed following the drawing and here is the first support, a little file work and the support is ready.







For the other 3 supports I used the first as a model and I repeated the above steps






At this point I mounted 4 fans enlarging the holes where necessary, and here is the final result. This fans block will mount both laterally that in the front and in the rear that at the end will be identical.





Finally I placed the fans block in its final destination but it is about 4 mm larger, I am studying the best solution, however, there is space for sawing laterally.



I also tried the block in front and back and I really like the effect.
Surely I will work before the front, which I think is easier and then I'll use it as a template for the rear.

 

To facilitate placement of the side fan block I sawed facades side of the 900D, leaving only the bare minimum for fixing Cooling Towers, about 1 cm.




I put the paper tape on the facades of the case.




Given that these are in contact with the sides TdR to avoid removing unnecessary parts, outside there is in fact the aluminum profiled, I reassembled the 3 parts and marked along the Cooling Tower profiled the protruding parts of the case.




Once I have removed everything I cut the marked parts







Now the side fan block has the possibility to come out sideways of about 2 mm per side.







Finally I tried to compare the space inside with the original PSUs supports, as I suspected, I cannot put the 2 PSUs on the same side, I'll put one front and one rear.

The solution of putting all 2 PSUs on the same side although more traditional, in reality convince me less because it would have gone to impact heavily on the air flow creating a block.

 

I have accumulated so many leftovers that I have a small materials warehouse, considering the measures 160 x 150mm and adding a margin of 20 mm on each side, that then I'm going to bend inward to secure everything to Cooling Towers.
I had own the aluminum sheets of 200 x 200 mm. I put the paper tape marked at 190mm, cut and filed, all 4 panels






I reported the project drawing on the face covered with paper tape, showing both contours that openings.



I removed with the dremel the parts; actually for the circular hole I wasn't prepared, in this case I removed roughly with a Dremel, at the end proved to be very effective the file (which has a side semicircular), and my hand surprisingly suited to the movement and I placed Aquatube and Filter.




I marked the holes for the screws, easy thing for the filter, much less for Aquatube .....





As always, I took the opportunity to have the piece mounted for testing the final structure of the piece.

 

I have therefore better equipped me, I found two cups 64mm and 60mm, here I make a comparison with the hole in the old piece with the hole of 64 mm





You will not believe but the 64mm cup, which seems perfect, makes a hole too wide, where I haven't margin to fix the hole with the file, also because there are the mounting holes around. Instead of the 60mm cup, who leaves 2 mm on each side to remove the file by hand with give a perfect result!

I have redesigned support putting the filter behind with the attacks upwards, I opted for a square hole to fit the screws holding the glass.



I modified a bit the technique used previously, I drew the design on the panel, made ​​a hole in the center of the circle, used the 60mm cup for the circular opening and the Dremel for that square.





A big file work to remove several mm in both holes, I must admit that I'm re-evaluating much of the file work, you can obtain a considerable accuracy.
For the mounting holes for the filter there are no problems just mark them, for acquatube this time I was much more accurate, I have done a in holes calque with a paper and pencil and then I cut the inner circle corresponds to the size of the glass.
And here is the result, after subtracting 2 cm margin to fold for fixing, the 3.5 cm will allow me to put the 90° connector or make a turn with tube.







One particular thing I want to highlight this project is that I have to make the pieces more times: towers are 2; supports for the Monsta are 4; the supports for the 4 fans are 4; openings for 4 fans in the case are 2 and so on.

Also in this case found the method and made ​​the piece, in reality I must do 4 of its.
I used the first made as a template, I fixed with clamps, marked in pencil, mark the center of the circle, drilled with the drill, and then I used the same technique used previously.

And 2:





And 3, and 4




But it wasn't so easy, I have therefore accumulated some wrong pieces , but I had the satisfaction of seeing the look without the paper and film.

 

Still a bit work to file



I marked on all the pieces a 20 mm edge and 45 mm from the corners, a part that I have to remove so that the piece fits on the Cooling Tower where in the corners there are the L-type brackets, which are precisely of 25 mm.




I folded the pieces to get the form suitable for fixing








I have tried the supports in their slot and have to say that perfection was what I wished




To get an overview I put all the parts in place, here's a front and rear view, plus two from the top.

 

I'm passed to the fixing stage, I marked the positions of the screws with a pencil and nail, then I checked with Stainless Steel Filter that the position of the screws don't obstruct the fittings or pipes




And here I present to you my new Tools taken for this Work




I positioned the support on the Cooling Tover , blocked all in position with a metal sheet outside and some clamps.
I drilled with the new joint for the drill in the marked points, I screwed up and the result is really very solid!






How you can imagine I tried again the Aquatube and the Steel Filter on the support to see the effect, but especially the interior spaces arrangement.

 

Good lord! Do you ever rest?
I'd suggest you slow down the updates just a wee bit, and put a bit more effort into making them. Doing so would most likely net you more followers. Also, take a little time to reply. Your english isn't too bad. Not exactly amazing, but it's decent.

 

OH is a awesome work!
stay tuned!

 

Thanks siliconfanatic.I know my English is just so so. I'm trying to update this worklog with the current state of my work as have been requested by some of my sponsors

Thanks Bro, but you already know

 

I realize the supports for 4 front 140mm fans and a fastening system.
The fastening system that I thought having to anchor the 900D original front frame, instead looks great anchored to the structure of Cooling Tower as I tried last time.

But I cannot fix a bar posterior to the vertical profile of Cooling Tower, as I had originally thought because protruding to the inside of some mm over the fixing screws, so probably it would touch the radiator, so I thought of another solution .....

But from the beginning, I realized the fan supports








I also did a trial installation of the fans on all the pieces, I was very pleased indeed all the pieces were perfect on the first try and did not require adjustments.





At this point I realize the horizontal bars that I will use to attach the fans supports to the main structure






To make the bends I used a Profiled of 2.5 cm as a base and one of the cut pieces as a block.
I repeated the operation and I got the desired result!







Then I passed to make placement tests





I continued work on the front fans blocks, starting from the prepared parts







To keep the two sides in the correct position I put 4 fans.
I then placed the block on the supports where I have to fix in order to verify the measures taken, everything matched.




I blocked the piece in place with 2 screws, I drilled and screwed. Repeating the operation for both the media got the complete piece.





I positioned the piece with 4 clamps and a profile under which prevented the support to protrude inward, I drilled and fixed







I tried to place the front exterior of the 900D and everything fits, also on the inside.




I then did the same steps for the other fans block







Here are both supports mounted




These are the blind nuts between which will choose for fixing the cover.






PS.
I did a little finishing touches on the front and rear fans blocks.









I reassembled everything and here is the result:

 

I then worked on the rear panel with the slot for the Mobo and VGAs, I removed it






and I fixed in its new location






I then perfected the rear opening for the 4 140mm fans, removing part of the edge










this is the result

 

I used Dimastech's bay supports and I've fixed them on the Cooling Towers










































Final effect

 

I then modified the front where now will be 4 140mm fans







At work
















and here's the new piece fitted




These are the two fronts that I want to become equal



so at work!







On these parts I also want to add a LED system, which illuminates laterally




I therefore build the support for such LED system













and I have fixed one of them on the frontal










here is the final effect

 

I have to do the same work on the rear panel of the 900D, with some difference
























I had to build a edge on which to attach the aluminum plate










as for the frontal I built a support the LED system





and I assembled it



On the rear panel, however, there were no openings from which I want to get out the light, I therefore created and perfecting also those in the frontal















and here as look the fans block in its slot

 

Other small changes to the 900D, I went to cap the many holes that are present on the bottom so that when it is in operation and equipped with filters the entry of dust will be minimal














I then re-riveted the case parts together even staring the aluminum band and reassembled the fans support below





I have also perfected the attachment of the side panel

 

Meanwhile arrived from the USA also EVGA X-79 Dark's WBS made ​​by modder nateman_doo





And I inspired by the legendary (and crazy) Bill Owen of Mnpc Tech (do you know him ?) I designed to realize removable grille covers on all the houses of this kind:



However, I haven't found in Italy the perforated sheet such as that used in the work by Bill (with 4 mm hole, 5 mm pitch, Offset of 60°, 1 mm thick, preferably aluminum), in huge quantities and good price.
I then found an Italian site, OIB, which makes customized metal sheets and I've ordered a huge quantity, 4 mq cut into 4 sheets of 1 x 1 m.



I also designed the several aluminum frames to be ordered from lasermio.it





Then came the sheet ordered by OIB, that fully meets expectations, notice the difference with the one found in the hardware chain, the % full / empty is very different:





and the parcel lasermio with frames










so I can proceed with a new phase of construction!

 

I went back to take care of the central part of the case or what was the 900D bottom.
I started trying to stabilize the 4 vertical fans blocks that were only supported at the ends.










I mounted a pair of fans to evaluate how fixing screws protruded and have done various tests with the frame of the grid.









At this point I switched to fix the 4 fans side blocks










On the back side there was not enough space to insert support












Other support

 

I have improved the support for the grid









and I went to fix it









Repositioned everything I went to try and screw the fan block






It remained to realize the recess for the screws that protrude laterally







By tightening the screws of the frame I noticed that it tended to bend over slightly inward, clearly my monkeys could not let it go this thing and began to howl loudly in my head until I settle them.








The result has fully satisfied me and finally even the monkeys

 

But we move on to the creation of the famous grids

I cut and clean the perforated sheet mesh







put in place and glued with bi-component








And here's the first grid ready!

Bro was so much that I wanted to do it ! this idea was born even before the project's Mod, thanks to Bill Owen for having unleashed the monkey!




Some tests






On the outside I have perfected a couple of details which I was not satisfied





I then placed the outside grill, blocked, drilled and fastened.





I went to take care of the grids of the 2 single fans positioned on the bottom of the 2 Cooling Tower :

both internal grids:







and external:






And here is the result of 4 grids

the internal




and the external



are then going to try them in their final position






and then positioned it on Coling Tower, remember that this is the bottom, the tower is upside down in the picture