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Scratch Build – In Progress Project: Blue Horizon - "MOTY" Nominee

Discussion in 'Project Logs' started by riekmaharg2, 8 Jul 2010.

  1. bulldogjeff

    bulldogjeff The modding head is firmly back on.

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    Now that looks seriously interesting. Tell ya what mate, you'd earn yourself mega kudos if you could pull that design off .

    from the drawing, would I be right in assuming that its passively cooled.
     
    Last edited: 2 Feb 2011
  2. riekmaharg2

    riekmaharg2 has completed the PowerCore scratch build

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    Yep due to it having so much surface area
     
  3. bulldogjeff

    bulldogjeff The modding head is firmly back on.

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    I'd be very tempted to try to get a couple of small fans along the bottom just to give it a helping hand to vent any hot air Just in case the side panel makes it all a bit restrictive because there will be very little air flow with it fitted. I'm not saying it won't work, thats just my way of thinking.
     
  4. riekmaharg2

    riekmaharg2 has completed the PowerCore scratch build

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    Yeah I was thinking that too. If there isnt enough airflow I'll use one of those fans from graphics cards which blow air horizontally, that way I could put in the fan/s in the middle of the heatsink where they cant be seen like the PS3 has. Hopefully I'll get away with passive only cooling :)
     
  5. bulldogjeff

    bulldogjeff The modding head is firmly back on.

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    Just slap a great big 220mm jobby on there, then make up a cover so it looks like the spare wheel on a 4X4...maybe not, but it's an idea if everything else fails....lol
     
  6. riekmaharg2

    riekmaharg2 has completed the PowerCore scratch build

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    Yeah lol, thats actually a good idea I bet I could work it in so it looks cool, if everything fails.
     
  7. jrs77

    jrs77 Modder

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  8. Monkey Puzzle

    Monkey Puzzle Minimodder

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    That aluminium is going to look amazing when polished. Really great work. :)

    I'm not sure on the massive block design though - I count 52 ninety degree turns in series.... I think I remember some testing on XS equating 10 90 degree turns to a cpu water block (can't remember which). Going to require several powerful pumps to have enough pressure to get the water round the loop at a reasonable rate. It might be worth looking at having the water split to run in parallel channels instead to minimise pressure drop.
     
  9. Monkey Puzzle

    Monkey Puzzle Minimodder

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    You can also get axial fans - that's the solution the cape cora/konvekt-o-matik finned tubes used for active cooling. Or just try it without the covering outer metal cover.
     
  10. Xye

    Xye What's a Dremel?

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    Intriguing....

    It looks as though the block and the fins are two separate pieces. How will you join them to get maximum heat transfer? Surely it would be better to make it all as one piece?
     
  11. riekmaharg2

    riekmaharg2 has completed the PowerCore scratch build

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    I need the flat edges to be on both sides of the heatsink so I can trasnfer the heat from the block, through the heatsink, and then into the heat sink cover. You can also get more fins per inch with a folded fin. An extruded one would also weight too much.

    Thanks Monkey Puzzle, Yeah sounds like a good idea :thumb:, i'll try and make a nice symmetrical design for it.

    Yep could do, if passive turns out to be not enough I'll try all the different ideas poeple have posted up and see which one works best. The covering metal is going to be the heatsink aswell.

    I would definately like it to be one peice but I dont think its possible, as I want the heatsink to transfer heat to the heatsink cover as well as just the heatsink itself, so I get even more surface area. I will join them with thermally conductive resin and thermal paste. I will alternate between the two as I go across the fins.

    I also forgot I'm gonna have to cut the panels in half before I polish them.
     
  12. stuartwood89

    stuartwood89 Please... Just call me Stu.

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    Just read through this and I like it so far. Keep up the good work.
     
  13. voigts

    voigts What's a Dremel?

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    Those cast pieces really turned out fantastic after all of your sanding work. I would imagine that they'll have to be brushed to match the rest of the case though, not mirror polished.

    Your alu heatsink is an interesting concept. I really do wonder though if your folded idea would net better heat transfer than using the large heatsinks linked to. What you might gain in surface area, you might loose in convection airflow over a heatsink.
     
  14. The_Gnu

    The_Gnu 8-bit addict

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    I dont't wanna be a party pooper butt I too have some conserns about the new heatsink design. Especially if your aiming for it to be passive. I think I read some where that optimal distance between fins are around 8-10mm for natural convection cooling (dependent of the height of the heatsink) and thats without a heatsink cover . Whats the spacing in your case?

    Adding that heatsink cover will propably be negative for the natural convection inside the "heatsink". However If you add a fan inside, I see no reason for it not to work.

    How do you intend to make those heatsinkfins? It seems very complicated.

    Anyway, I don't wanna set back any of your ideas this is just some thoughts. The best answer you get by trying. So..good luck what ever way you choose.
     
  15. jrs77

    jrs77 Modder

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    That's why I suggested using an extruded aluminum-profile aswell.

    It woul make the whole heatsink way less complicated and the spacing of the fins of an extruded profile is allready calculated to work properly.

    You simply route the channels for the water into eiter the acryilc or the heatsink and slap them both together and voilá... huge passive radiator done. Adding a fan to improve performance if you need to would aswell be very simple.

    These -> Cape Cora 1042 would be even better tho and they're especially designed for what you want to do and readily available.
     
  16. The_Gnu

    The_Gnu 8-bit addict

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    @jrs77 Yeah, using an already fabricated heatsink would most likely be the easiest and best way to go. On the other hand, I get a feeling that riekmaharg2 is a pure DIYer who thinks that would have been a bit too easy. I asume he wants to make the radiator/heatsink by himself.:dremel:
     
  17. riekmaharg2

    riekmaharg2 has completed the PowerCore scratch build

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    Thanks stuartwood89 :thumb:

    Yeah I'm going to try to get the mirror finish to work even if it means painting some other areas of the case, or if it just doesnt look right at all I'll probably get them anodised as I cant get a even brushed effect due to the compound curves.



    I was going to get the folded fin heatsink made by a company who specialise in it, I'm also going to ask them what sort of spacing is best for passive cooling. I would never be able to get the fins neat enough for it to look nice if I made it myself. Theres also bonded fin heatsinks which are like extruded ones only they have more fins and are made from much thinner aluminium:

    http://www.ppmpower.co.uk/bonded_fin_heat_sinks/

    Theres too many choises :lol:

    The Cape Cora's as might impressive but there a bit to wide, I'm trying to blend the radiator in with the case rather than just sticking it on the side, thats also what I wanted the heatsink cover for mainly. I'm also worried about the case being to heavy on that one side as its so light I dont want it to fall over lol.

    Do you still think an extruded one would be better or a professionally made bonded, or folded fin heatsink?
     
  18. riekmaharg2

    riekmaharg2 has completed the PowerCore scratch build

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    Heres the next update:

    I didnt get as much work as I wanted to get done, as someone broke the milling machine chuck and I had to get a new one but here it is.

    I first measured up the top panel and marked where I need to cut it:

    [​IMG]

    I then made a little jig to hold the panel in the correct position so that I could saw it with the slot saw on the milling machine:

    [​IMG]

    [​IMG]

    [​IMG]

    Heres the two halfs:

    [​IMG]

    All I need to do now is chop the remaining bit off the larger half then figure out a way of making the edge perfectly striaght, as the milling machine table wont move far enough to make the cut all in one.
     
  19. jrs77

    jrs77 Modder

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    If you can get the heatsink professionally manufactured, then that changes my point there, as a professional bonded one is just as good as an extruded profile.

    I was of the belief that you wanted to make the heatsink yourself there actually :D
     
  20. riekmaharg2

    riekmaharg2 has completed the PowerCore scratch build

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    Ah sorry I should have said as I make everything usually.
     

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