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Scratch Build – In Progress Project: Aluminum Water Cooling Case

Discussion in 'Project Logs' started by Spotswood, 17 Apr 2011.

  1. Spotswood

    Spotswood Custom PC case builder

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    This is a project/build log for an aluminum case designed specifically for a large water cooled rig, specifically:
    • 3 x 140x4 radiators
    • 1 140x3 radiator
    • 10-slot motherboard tray

    [​IMG]

    [​IMG]



    So far, the aluminum constituting the frame of the case has been cut:

    [​IMG]

    Stay tuned!
     
    Last edited by a moderator: 22 Apr 2011
  2. Nexxo

    Nexxo Queue Jumper

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    Project log should contain pics of work in progress, please. Moved to Modding...
     
  3. Wicked_Sludge

    Wicked_Sludge My eyes! The goggles do nothing!

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    thats a lot of cooling. do you know what hardware is going in it yet?
     
  4. Spotswood

    Spotswood Custom PC case builder

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    Unfortunately, no.




    The basic frame of the case is done, which consists of .5x1-inch u-channel with its ends plugged with blocks (pictured in the first post), press-fitted and pinned with a #4 screw along with some 1-inch angle:

    [​IMG]


    [​IMG]


    [​IMG]


    The assembled case frame is too tall to fit in the camera frame. hehe

    [​IMG]



    The frame looks kind'a "meh" until I bolt on the gorgeous anodized quarter rounds.

    [​IMG]


    [​IMG]
     
  5. Nexxo

    Nexxo Queue Jumper

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    ...and there's the project log. Moving right back... :)
     
  6. KidMod-Southpaw

    KidMod-Southpaw Super Spamming Saiyan

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    That's going to be an absolute monster of a case! Great start.
     
  7. Gravitea

    Gravitea New Member

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    I have a quick question, you are using U channel aluminum for your frame, how much stronger is it compared to angle aluminum? Also, can 3mm angled aluminum be strong enough to make a watercooling case?

    Thanks
     
  8. Spotswood

    Spotswood Custom PC case builder

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    I'm not an engineer, but the u-channel feels to be at least as twice as strong as an angle (as to be expected).

    I personally wouldn't build a case out of 3mm angle, but ymmv.

    Good luck!
     
  9. StonieX

    StonieX New Member

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    Nice work on the main frame :thumb:. It looks pretty solid and decent. I also think the U-channel were a good choice because of the stability against twisting ;)
     
  10. nlancaster

    nlancaster New Member

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    1/16th aluminum is plenty strong enough to build an entire case from. Just have to have some triangluation built in. Either angled braces or some form of solid plate. and example would be the mid play in a Lian-li style case, and the motherboard tray. Attach those plates along at least three sides and the case will stand up great. And be lightweight.

    Spotswood, I love your idea for scre blocks in the aluminum channel. I will have to still it for future builds. :D

    Where did you get the quarter round extruded aluminum parts?
     
  11. voigts

    voigts New Member

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    You are really keeping busy these days. very nice as always Rich.
     
  12. jhanlon303

    jhanlon303 The Keeper of History

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    The young have no patience.

    john
     
  13. Nexxo

    Nexxo Queue Jumper

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    The young should respect the rules.

    Nexxo
     
  14. Spotswood

    Spotswood Custom PC case builder

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    The two shelves were cut from a .10-inch thick 5052 via my trusty router, a straight edge and a downcut spiral bit.

    [​IMG]


    At the back corners of the shelves, two .5x1-inch cutouts were routed out via a temporary router jig.

    [​IMG]

    [​IMG]


    The rounded inside corner left by the .5-inch flush router bit were filed square.

    [​IMG]


    FWIW, here's the difference in the thickness of the aluminum sheeting I use compared to everyone else.

    [​IMG]


    Finally, a mockup of the shelf inside the frame of the case:

    [​IMG]
     
  15. Spotswood

    Spotswood Custom PC case builder

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    mk Technology Group.
     
    Waynio likes this.
  16. Waynio

    Waynio Relaxing

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    Spotswood, you give me faith that I don't need an expensive mill :D:clap: & instead just need to buy a router & get good at using it & making custom jigs.

    What is the thickest aluminium you have routed? also do you have to do it in gradually deeper depths like a couple of mm at a time?.

    Your cases rock :D sturdy & great looking :thumb:. +rep
     
  17. Spotswood

    Spotswood Custom PC case builder

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    1/4-inch is probably the thickest I've cut so far, and yes I did that in two passes. Everything else I do at full depth. However, when cutting raw material I'll cut them oversize with a 3/16-inch mill/bit, then sneak-up to the desired dimension with a 1/4-inch spiral down cut bit i.e. the final pass is only removing ~.5mm of material for a nice smooth finish.
     
  18. Waynio

    Waynio Relaxing

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    Thanks for the useful info Rich :thumb:.

    Wow it must be fun making mad extreme cases :D.
     
  19. Radcarton Mods

    Radcarton Mods I do graphics

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    Huge great looking case on the horizon..its amazing how those two pieces of quarter rounds transform the basic frame..great work so far :thumb:
     
  20. Spotswood

    Spotswood Custom PC case builder

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    The 5.25-inch drive bay rails finally came back from a local fabricator.

    [​IMG]


    And a 140x4 rad arrived in the shop.

    [​IMG]

    [​IMG]
     

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