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Scratch Build – In Progress Project - PowerCore

Discussion in 'Project Logs' started by riekmaharg2, 26 Jul 2020.

  1. riekmaharg2

    riekmaharg2 has started the PowerCore scratch build

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    Thanks both :grin:

    This took me longer to figure out than I care to admit lol, but eventually managed to clamp the top panels in a way that I could trim down the mounting tabs a bit:
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    All the bits arrived from the laser cutters too :)

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    These are the trays for the Motherboard, HDD, and Graphics card
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    Next up was a hellish amount of polishing, this must have taken me about 18 hours all together, as I had to start off with 80 grit sand paper to get out the deep dents in the aluminium where the bends were, and a few deep scratches. I started off with an orbital sander and discs from 80 - 800 grit, then swapped over to foam sanding discs with WD-40, then finally a polishing disc for a polishing grinder and the brown metal polishing compound.

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    For the tricky to reach spots I used a multitool with the sanding head
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    Then I stuck some foam to the blade attachment (Didnt work without the foam from the pic above), and stuck some wet and dry to get the areas I couldnt fit the normal sanding head in.

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    And here's the result, its still needs a final polish to remove some of the streaks but its almost there
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    Try to imagine it in a dark gun metal grey like the trash can Macs, once I get it anodised :grin:

    I've also tested the fan, I printed with one first
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    However the part right behind the fan motor turned into a speaker for the vibration unfortunately, so I've tweaked the design to this now:
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    Im going to have to make it out of aluminium for the real thing though, as this isnt rigid enough, for efficiency I've made the blades of the fan very close to the housing, so any flex in the fan mount is very bad. The mount is held with bolts and those little rubber mounts you get for drone controllers.

    I then gave the aluminium a quick sand (ill probably bead blast them for the final finish. I also glued some fabric to the edges of the 3d printed sides so it slides into the bottom of the case for nicely. I'll probably paint the rest of the visible parts of the prints:
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    And brass thread inserts for the mounting screws:
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    Here is it in the bottom of the case:

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    4LIEN, No X, Taritha and 3 others like this.
  2. Cheapskate

    Cheapskate Insane? or just stupid?

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    Nope. You have to leave it shiny and beautiful.
     
    Vault-Tec likes this.
  3. kim

    kim hardware addict

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    :rock:what a work :wallbash:...stunning design and execution :clap:
     
  4. miculago

    miculago What's a Dremel?

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    I see it, I love it, but... cannot believe this is real. Awesome work!
     
  5. dan297

    dan297 Modder

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    What a bloody fingerprint magnet. Give it a dull matt black paint finish, mate...

    No seriously, I cannot believe those where the same parts :eeek:
    Awesome work :thumb:
     
  6. 4LIEN

    4LIEN Modder

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    All polished is absolutely stunning! :jawdrop:
     
  7. Cheapskate

    Cheapskate Insane? or just stupid?

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    Not in the post-covid extra sanitary hand washing era. As long as he's not milling and oily, or chalked up from playing billiards, he's good.
    ...He may end up with a d*ck print on it if any modding/milling enthusiasts find where he lives, though. :lol:
     
  8. dan297

    dan297 Modder

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    Better not to show off at a LAN party :grin:
     
  9. riekmaharg2

    riekmaharg2 has started the PowerCore scratch build

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    Thanks all :)

    I think it would be a crime to cover up all this alu that took this much effort to create lol :grin:

    haha :grin:


    I've finished the polishing of the case shell and top now, however the anodisers are concerned about being able to get an even black tint across both the sheet, and milled parts, soooooo, I think I'm gonna get it clear lacquered instead, with a "candy" tint to keep the mirror effect but have a black tint. I found this lacquer online: https://www.cerakote.co.uk/shop/cerakote-coatings/performance-clears/clear-aluminium-mc-5100/
    Which seems to be super tough, sticks to polished aluminium, and a company near me sprays it, they've not tinted it before though, so I'm currently waiting for them to test tinting it, before they give me a price.

    Anyway onto the build....

    I managed to find an arbour for polishing wheels that fits my grinder, so this made things alot easier to finish the polishing:
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    Next up was sanding and polishing the blades for the vents in the top and bottom in each corner:

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    I then realised all the hex's I had laser cut all had a little bit sticking out so I had to file them all off, took ages:
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    I then sticky taped them to a peice of wood, then sanded and polished them:
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    I then glued them all to a 1mm polycarbonate sheet, along with the rest of the panel and using a 3d printed holder to get them centered. Each of these will be cut off this sheet later. The battery was to press the hex part out of the 3d print holder:
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    That was then set aside, while I modded some G1/4 plugs:
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    I'll need to probably chemically strip off the plating and paint on these, and get them re-chromed to protect the aluminium.

    It passed the pressure test :)

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    I also found these sweet fitting from Barrow, that have RGB leds built into the compression fitting, which Ill be using with these water function blocks:
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    I then polished and hand bent the 1mm alu panels that go behind the tubes on the outside of the case:
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    For the backlight, I thought about using a Tv backlight, but it didnt have the light spreading ability I was looking for unfortunately:

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    So I've had to resort to tablet LCD back light sheets:

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    I wore gloves for this as the sheets mark very easily:
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    They are made of multiple different sheets of plastic that act like, light diffusers, and polarizing filters, which means you can shine light into a small area, and it spreads the light very evenly:

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    I glued, and taped the edges onto the back of the panel, I'll probably stick some fabric or something on the back as well to cover it all:
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    This is how it will look, for this test its just a small RGB strip on one side, when its complete it will be a strip on both sides, and it will be the length of the whole side:

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    Now I need to find more broken tablet screens lol

    And the final part to the update. I've had the water distro block for the gpu 3D Printed via HP Multi Jet Fusion, so its water/air tight:

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    I then tapped the holes, and milled flat the surfaces:
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    Then sanded it all smooth:
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    The O-ring channel is a bit tight, but it should still do the job once its compressed:
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    Looks like the o-ring works, and I pressure tested, all ok :
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  10. dreps

    dreps Minimodder

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    euh.... 3D printing a distribution block...
    That's next level
     
  11. Cheapskate

    Cheapskate Insane? or just stupid?

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    Beautiful! :D Love the 10,000 rpm buffing wheel. Did you get any gunk on the ceiling?
    I've been really curious about the HP printers since we started farming out prints for mods. Dare I ask how much that print cost? I have a sneaking suspicion that it was very pricey.
     
  12. riekmaharg2

    riekmaharg2 has started the PowerCore scratch build

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    I try my best :grin:

    Haha, mostly all over me lol, works well though. Its variable speed though thankfully, so had it on about half.
    Its not too bad a price I thought, it was £66.16 including VAT and delivery, from https://lancashire3d.uk/, so not too crazy like if I had used metal printing.
     
  13. censored_Prometheus_

    censored_Prometheus_ Minimodder

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    Great idea, excellent workmanship and amazing quality of the material processing! Watching the birth of a masterpiece. :dremel:
     
  14. riekmaharg2

    riekmaharg2 has started the PowerCore scratch build

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    Thanks :grin:

    Finally got an update, I tried for a quite a while to find a company within 150 miles that would black chrome plate aluminium, as a one off but I had to give up the end. I then tried various black chrome paints, and tints but I wasnt happy with any that I found. So its pains me to say it, but after all that polishing I've ended up with just going for a super glossy polished black paint. Not what I originally wanted however I think its still turned out very nice.

    I also got back the rest of the inner parts which have been ceramic coated with Cerakote. Sorry about the fuzzy pictures of these black ones, my phone camera didnt like it.

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