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Scratch Build – In Progress Project HELIOS - Mod or Materials Sciences Class - You Decide - 4.27.11

Discussion in 'Project Logs' started by Langer, 18 Sep 2010.

  1. Langer

    Langer Jesse Lang

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    HELIOS, the Titan god of the sun. Tireless is he who is like the deathless gods.
    As he rides his chariot, he shines upon men, and piercingly he gazes with his eyes from his golden helmet.
    Bright rays beam dazzlingly from him, and his bright locks streaming from the temples of his head gracefully enclose his far-seen face.
    A rich, fine-spun garment glows upon his body and flutters in the wind: and stallions carry him.
    Then, when he has stayed his golden-yoked chariot and horses, he rests there upon the highest point of heaven, until he marvellously drives them down again through heaven down to the lasting earth.

    [​IMG]

    Design Features:
    - Crafted from the worlds highest grades of composite materials and carbon fiber.
    - Showcasing some of the finest watercooling components and computer hardware.
    - Designed to hide every fastener, nut and bolt.
    - A lack of case windows leave the motherboard bare and exposed.
    - High-tech and specially engineered ceramic foam filters and stainless steel mesh keep out dust.
    - Made from virtually indestructible panels over 8MM thick.
    - Taking advantage of air pressure zones to keep hardware dust-free.
    - Fully removable motherboard tray without disconnect or power-down.
    - Highly modular design makes part-swapping as simple as possible.
    - Sleek minimalist design is a call back to swiss modernism and bauhaus principals.
    - Design and fabrication methods tailored to an extreme rapid fabrication cycle.
    - HELIOS is to be a scratch build mod, truly, like no other.

    Hardware List:
    Computing:

    Processor - 1x unknown
    Graphics - 3x nVidia GeForce GTX 480
    Motherboard - 1x unknown
    Memory - 12GB unknown
    Power - Corsair AX1200
    Storage - 8x 120GB SSD
    Display - 3x Asus VW266H 25.5"

    Cooling:
    Processor - 1x AquaComputer Cuplex Kryos XT
    Graphics - 3x unknown
    Motherboard - 1x unknown
    Radiators - 2x HW Labs GTX420 (3x140mm)
    Tubing - 20' Tygon AS600038
    Fans - 13x NB-BlackSilentPro PK-3
    Pumps - 4x Laing DDC-1plus
    Pump Tops - EK-DDC Dual Top V2
    Memory - Mips RAM Kühler6
    Fittings 1 - 10x 3/8" Straight Rotary Fitting
    Fittings 2 - 20x 3/8" 45 Degree Rotary Fitting
    Fittings 3 - 20x 3/8" Angle Rotary Fitting
    Fittings 4 - 10x Low-Profile Stop Fitting
    Fittings 5 - 16x Fitting Spacer
    Fittings 6 - 16x Mini Fitting Spacer
    Fittings 7 - 8x No-Spill Quick Disconnect Female
    Fittings 8 - 8x No-Spill Quick Disconnect Male
    Fittings 9 - 4x 2-Slot Crystal Sli-Link Tube
    Fittings 10 - 3x Mini Sli-Adapter

    Fasteners and Hardware:
    Polyethylene Spacer - 40x 3/16”OD x .115”ID x 3/8” (McMaster - 92825A009)
    SS Dowel Pin - 50x 3mm x 6mm (McMaster - 91585A051)
    SS Press-Fit Threaded Insert - 5x 1/4-20 x 1/2” (McMaster - 92394A116)
    SS Press-Fit Bushing - 4x .257”ID x 1/2”OD x 1/4” (McMaster - 8492A155)
    SS Knurled Thumb Screw - 4x 1/4-20 x 3/4” x 1” (McMaster - 91830A577)
    Wool/Rayon Adhesive Back Felt - 1x 24” x 32” x 3/64” (McMaster - 8770K3)
    SS Low Head Socket Cap Screw - 75x M4 x 30mm (McMaster - 92855A425)
    SS Knurled Thumb Screw - 24x 6-32 x 1/2” x 1/4” (McMaster - 91746A536)
    SS Low Head Socket Cap Screw - 25x 6-32 x 3/4” (McMaster - 93615A210)
    SS Self-Lock Flat Head Cap Screw 25x 10-32 x 1” (McMaster - 92805A268)
    SS Male-Female Standoff - 18x 6-32 x 3/16”OD x 3/16” (McMaster - 91075A461)
    Hinge / Lid Support - 2x 1.744” x 5.313” (McMaster - 14785A51)

    Materials:
    - 8MM thick CNC cut carbon composite panels crafted to the strictest military specifications
    - 2MM thick thermoset carbon composite panels made for aerospace applications
    - Stainless Steel hardware throughout
    - Stainless Steel micro-weave mesh
    - Felt dampening
    - Polyethylene to reduce friction in modular areas.
    - Custom engineered ceramic foam air filters

    Specifications:
    Size - 206mm Wide - 610mm Tall - 610mm Deep
    Weight - unknown
    Performance Statistics - unknown


    Design, Prototypes, Mockups and Fabrication log to follow.
     
    Last edited: 28 Apr 2011
  2. Langer

    Langer Jesse Lang

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  3. Langer

    Langer Jesse Lang

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    Current Progress
    [​IMG]
     
    Last edited: 18 Jan 2011
  4. Langer

    Langer Jesse Lang

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    INITIAL CONCEPT ILLUSTRATION:
    Using Adobe's Illustrator I created a couple rough perspective drawings, so that I could get a better idea of the concept in my head:
    -At this point the plan was to construct the case in Aluminum.
    [​IMG]


    REVISION 1.0:
    [​IMG]


    REVISION 2.0:
    After talking with the community and doing some more planning myself, I made some changes to the plan.
    -Altered some of the chassis dimensions.
    -Trashed the idea of stacked radiators.
    -Relocated the pumps and reservoirs.
    -Added a downward facing PSU fan, which would later be scrapped.
    -Finalized the tubing layouts.
    -Changed from 360MM radiators to 420mm
    -Changed the fabrication material to Grade 38 Titanium
    [​IMG]


    REVISION 3.0:
    I again posted my designs for the community to critique and made some very minor alterations yet again.
    [​IMG]
    [​IMG]


    REVISION 4.0:
    At this point I was getting some really good feedback online and started putting it into practice.
    -I redrew the entire design with new dimensions.
    -Plotted the wiring paths.
    -Refined the tubing layouts.
    -Finalized the pump and reservoir positions
    [​IMG]
    [​IMG]


    PAPER PROTOTYPE:
    It was now that I decided to take my design and bring it into the physical plane. The medium I decided upon was cardboard and tape - the board I used is the same stuff one would use to matte pictures when framing.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]


    REVISION 5.0, current and FINAL revision:
    Happy with the prototype and the general concept, I decided it was time to finalize the plan and fix the little issues. This revision I've kept to myself until this now. I've made many very small changes to the plan.
    -I again completely redrew the design, this time with 8MM thick paneling.
    -I added small routered grooves where the panels fit together to better hide the seams.
    -Altered the relationships of components and their positions.
    -Finalized the design for the PSU cavity.
    -Beveled all the edges of the cuts - to compensate for the diameter of the 1/8" cutting tool on the CNC router.
    -I also swapped out the Titanium for a Carbon Fiber construction instead (I'm going to save the Titanium I acquired for another project down the road).
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
    Last edited: 18 Sep 2010
  5. Langer

    Langer Jesse Lang

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    I've been working with an engineer, and friend of mine named John Dalton, who has graciously offered up some time to throw together a 3D mock-up.

    He sent me off the first revision of his model today.

    There are couple of minor errors, due to my vague explanations:
    -In this model the motherboard backplate is flipped 180deg
    -The SSD mounts are affixed to the side panels instead of the rads
    -the motherboard tray is just floating in space.

    They are such minor issues that I have no problem at all sharing some previews with you.
    And John already agreed to rectify the issues for me on Monday.

    You can CLICK HERE for a live model preview which you can rotate around and navigate in 3D space.
    Unfortunately this HTML export from SolidWorks is only supported by IE, and on PC.

    Here's an ISO view with perspective.
    [​IMG]

    Side view with perspective:
    [​IMG]

    View of the back and side of the chassis.
    [​IMG]

    A couple of detail shots of the bottom.
    [​IMG]

    Note here how I managed to save some space by routering out some spots in the chassis and side-panel. These will allow for a couple extra millimeters for the pumps and PSU fan.
    [​IMG]
     
    Last edited: 19 Sep 2010
  6. Throbbi

    Throbbi New Member

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    Sold! Subbed and you haven't even started. That sounds like my kinda style.
     
  7. Langer

    Langer Jesse Lang

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    That's all I have to share for today.
    I'll have the revised model as well as some renderings to show you all next week.
    As well, next week, I'll share some pictures of the manufacturing process behind the composite panels. Perhaps even some shots of them being CNC cut to spec.

    *j
     
  8. miikrr

    miikrr New Member

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    I see you said you're saving the titanium for another project. Does that mean you wont be making a one-off version of this case with titanium?
     
  9. DeltaFX

    DeltaFX New Member

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    Titanium ? Isn't titanium a bitch to machine ?
     
  10. Razer2007

    Razer2007 Building Proxima

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    oh yeah it finally starts! I can't wait to see the process. And also this is the best planned mod Iv'e seen ever! Hope everything will turn out as planned. Subbed.
     
  11. LooseNeutral

    LooseNeutral New Member

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    Now where did I see this before. hmmm... No matter, it looks sweet. Glad to see this in the building stage. Sub'd :D
     
  12. Fabou

    Fabou New Member

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    Did I read 8 120 gb SSD?
    in RAID 0 that must be monstrous.
    Nice design having the Mobo in middle with sleek clean case around seem hot.
     
  13. llamafur

    llamafur WaterCooled fool

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    Water can cut anything :D


    I can already see this being a mdpc winner.
     
  14. DeltaFX

    DeltaFX New Member

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    Indeed, water does. But water doesn't work very well for milling.
     
  15. riekmaharg2

    riekmaharg2 has finished Blue Horizon

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    Wow, you've put alot of work into designing this. This is gonna be one heavy case.
     
  16. amagriva

    amagriva Member

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    Me too: Prometheus Start 18th Jul 2008, 00:17 - End ???:eyebrow:
     
  17. Langer

    Langer Jesse Lang

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    @miikrr - Thanks for signing up mate, and welcome to BT. And, yes you're correct in your comment.

    @DeltaFX - That's why we have lasers and machine shops.

    @Razer2007 - Thanks boss. I'm very excited to get this one wrapped up finally.

    @LooseNeutral - =)

    @Fabou - Muahaha! Thanks a lot man.

    @llamafur - Thanks a lot for the vote of confidence.

    @riekmaharg2 - The panels are featherweights compared to a metal alternative... but it's still going to be a beast on the scales. Thanks for the comment.

    @amagriva - I don't have a place to live and call my own, so the nearly complete Prometheus will stay in a box until I do. But it has come a LONG way since it was seen last... that'll be a surprise for another day.
     
  18. Razer2007

    Razer2007 Building Proxima

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    Am I boss?
     
  19. Langer

    Langer Jesse Lang

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    Boss, buddy, guy, dude, mate, man, bro... I'm trying to mix it up a bit. ;) lol
     
  20. Mork

    Mork New Member

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    Langer, WHY are you so awesome?? - Is it a special diet or something that makes you so awesome? :D

    Anyway, I'm really looking forward to seeing this one come along! :thumb:

    Subbed and in love :p
     

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