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Scratch Build – In Progress Project: Large Wooden Tower - Finished!

Discussion in 'Project Logs' started by Spotswood, 19 Sep 2009.

  1. Mechh69

    Mechh69 I think we can make that fit

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    Great start that thing really does look HUGE! The drawings look awsome cant wait to see more subbed.:clap:
     
  2. Spotswood

    Spotswood Custom PC case builder

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    Aw come on, its not that big. :D Here's the Corsair 800D in comparison:

    [​IMG]

    :D
     
  3. Spotswood

    Spotswood Custom PC case builder

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    I didn't like the quality of the front panel's plywood "B" side (the good "A" side faces the inside of the case), so I had to cut another piece and sandwich them together, "B" side to "B" side. By utilizing the existing panel as a template for my router, this extra task went fast. After rough cutting another piece of plywood, the two pieces were temporarily held together with double-sided tape. Then a pattern/flush trim router bit was used to "cut" the panel to size.

    [​IMG]


    The hole for the optical drives was routed out and the corners squared with a hand file.

    [​IMG]

    [​IMG]


    The next task was to route three 120mm holes in the front panel, but I discovered that the fan frame I was going to use as a router template wasn't stiff enough, which would have resulted in misshaped holes.

    [​IMG]


    The simple fix will be to glue on some 1/8-inch aluminum flat bar to stiffen it.

    [​IMG]
     
    Last edited: 2 Nov 2009
  4. RuSGaMeR

    RuSGaMeR No Pain No Gain...

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    NOT that BIG?????? That THING is HUGE!!!:D:D:D.........But on the other hand.....There's a LOT of ROOM to put ALL the stuff you WANT in it:D:D:D

    PS
    Looking Good so far.
     
  5. Spotswood

    Spotswood Custom PC case builder

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    There wasn't an easy way to fasten the fan "template" to the front panel safely, so I decided to fabricate yet another template. I cut some 1/4-inch thick plywood the same size as the front panel and I aligned the fan housing and used it as a guide to drill some holes (through all three layers of plywood).

    [​IMG]

    The plywood template was removed and the fan housing was "bolted" to it with some #8 socket cap screws i.e. the bolts were used to cut their own threads into the plywood.

    [​IMG]

    The plywood with the bolted-on fan were placed onto the workbench and a 1/2-inch pattern/flush router bit was used to cut out the fan holes:

    [​IMG]


    After all three holes were cut out of the template, the template was attached to the front panel and three more holes were routed out of it.

    [​IMG]


    The template was removed and the holes were cleaned-up with some 120 grit sandpaper.

    [​IMG] :D
     
    Mach likes this.
  6. Mach

    Mach What's a Dremel?

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    Very nice! Precise and an elegant solution.:thumb:
     
  7. Cheapskate

    Cheapskate Insane? or just stupid?

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    It's always fun to watch a quality wood case come to life.
    -Please promise us the client won't spray paint it black!
     
  8. Kaldskryke

    Kaldskryke Lurker

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    The first post says it will be stained black
     
  9. wbdog206

    wbdog206 not me

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    Sweet! nice work.
     
  10. Spotswood

    Spotswood Custom PC case builder

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    The decision to have the case stained black is regrettably, irreversible. :sigh: I just cannot guarantee that I haven't screwed up and gotten some blob of glue somewhere that would ruin the finish. Oak veneer plywood is like a sponge when it comes to absorbing glue. In the future, I will finish all of the parts before gluing/assembly, thus avoiding the "glue-up" problem altogether. Thus, I will have to charge more for an unfinished case. :sigh:
     
  11. Kaldskryke

    Kaldskryke Lurker

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    How many of these are you planning on making, Spotswood?
     
  12. Spotswood

    Spotswood Custom PC case builder

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    I'll build as many as people are willing to order. :thumb:
     
  13. Loom

    Loom What's a Dremel?

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    So who/what ordered this one? Personal client of yours? Do you have your own computer shop or do you build cases for a hobby/sideline? Sorry for sounding so probing, I just can't contain my curiosity. Even though many modders undoubtedly would like to make a couple of <insert local country's most popular note's colour here> ones I don't think it happens that often.
     
  14. Spotswood

    Spotswood Custom PC case builder

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    A member of XtremeSystems Forums, who was watching one of my design threads over there, commissioned this case.

    These are currently being built as a hobby, but that could change depending on interest. Over at XS a lot of members were drooling over a case design that this one is based on (that design was mention in Antony Leather's Is there such a thing as the perfect PC case? blog entry), but this one is being fab'd out of wood, which will probably lessen its overall appeal.

    I don't understand what you're getting at here. :confused:
     
  15. Loom

    Loom What's a Dremel?

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    It made sense in my head :idea:. What I meant is that many modders would probably love to make some money with their mods, I was just wondering if you're hoping for the same. Good luck, I'll keep an eye on this.
     
  16. Spotswood

    Spotswood Custom PC case builder

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    Case Top

    Yes, I hope many other water cooling enthusiasts will commission this case. :thumb:



    The top of the case is made from 1/4-inch plywood edged with 3/4 x 1-1/4-inch oak. The plywood was roughly cut to size on the table saw and then a couple of extra layers of plywood were glued to the edges in order to thicken it in preparation for gluing the 3/4-inch edging.

    [​IMG]


    The top was then trimmed to the desired width with the router.

    [​IMG]


    The edging was glued, scraped flush with a cabinet scraper and lightly sanded.

    [​IMG]


    Seam? What seam?

    [​IMG]

    :rock:
     
    Last edited: 6 Nov 2009
  17. Spotswood

    Spotswood Custom PC case builder

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    The ends of the top were cut with... Anyone? Anyone? ...a router fitted with a flush/trim bit. The "jig" used to make sure the cut was nice and square was a framing square taped to the workbench.

    [​IMG]


    Completed top:

    [​IMG]

    :rock:

    The top took a lot of time to complete. For the next 100 cases :rolleyes:, I'll have to come up with either a simpler design or a more efficient fabrication technique.
     
    Last edited: 7 Nov 2009
  18. stonedsurd

    stonedsurd Is a cackling Yuletide Belgian

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    :jawdrop:

    Wicked! :D
     
  19. Spotswood

    Spotswood Custom PC case builder

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    Left Side Panel

    First off, here's a pic of the case with the top.

    [​IMG]


    The side panels are made from 1/4-inch oak veneer plywood, edged with 3/4-inch oak, mitered at the corners. The plywood sits in a 5.2x10mm deep groove.

    [​IMG]


    Left-side panel done.

    [​IMG]

    :rock:
     
  20. Spotswood

    Spotswood Custom PC case builder

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    Somehow I managed to break both of my 5.2mm straight router bits, so work on the other side and front panels will have to wait a few days.

    Between the motherboard tray and the side panel is a removable "false" back that will strengthen the case, steady the motherboard tray and conceal all of the wiring. There is about 30mm between the "false" back and the side panel. :jawdrop:


    [​IMG]

    [​IMG]

    :rock:
     
    Last edited: 11 Nov 2009

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