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Case Mod - In Progress Project: PrometheusCU - Update #54 - May 28 2010 - Video Teaser

Discussion in 'Project Logs' started by Langer, 18 Jul 2008.

  1. Langer

    Langer Jesse Lang

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    [​IMG]

    Sponsored by:
    AquaComputer

    [​IMG]

    Watercool
    [​IMG]

    MIPS Computer GMBH
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    Corsair
    [​IMG]

    Quicklinks:
    Part 1:parts list and initial overview
    Part 2:drivebay enclosure prototype and radiator installed
    Part 3:radiator mount prototype
    Part 4:bottom tray prototype
    Part 5:to-be machined component design concepts 1 of 3
    Part 6:to-be machined component design concepts 2 of 3
    Part 7:to-be machined component design concepts 3 of 3
    Part 8:AquaComputer sponsorship announcement
    Part 9:small text update
    Part 10:watercooling parts delivery 2 of 7
    Part 11:graphics cards arrived
    Part 12:acrylic copper 2-way mirror delivered
    Part 13:pico-itx water cooling 1 of 7
    Part 14:introduction to lighting plans
    Part 15:more parts delivered & my workshop
    Part 16:lighting components/control delivered
    Part 17:watercooling parts delivery 3 of 7
    Part 18:pico-itx water cooling 2 of 3
    Part 19:carbon fiber test and small parts delivery
    Part 20:Watercool sponsorship announcement
    Part 21:prototype aluminum parts cutout 1 of 3
    Part 22:pico-itx water cooling 3 of 3
    Part 23:watercooling parts delivery 4 of 7
    Part 24:misc hardware delivery
    Part 25:case feet concept design
    Part 26:Watercool Heatiller Rev3.0 CPU block released
    Part 27:keyboard mods 1 of 4
    Part 28:keyboard mods 2 of 4
    Part 29:watercooling parts delivery 5 of 7
    Part 30:second pump installed
    Part 31:more parts... more air
    Part 32:watercooling parts delivery 6 of 7
    Part 33:GFX stealthing mirror 1 of 2
    Part 35:GFX stealthing mirror 2 of 2
    Part 36:nylon multifilament cable/tube sleeving delivery
    Part 37:part diagrams explained
    Part 38:massive part delivery
    Part 39:graphics card power wiring 1 of 3
    Part 40:graphics card power wiring 2 of 3
    Part 41:watercooling parts delivery 7 of 7
    Part 42:raid hardware, and replacement motherboard delivery
    Part 43:final part designs complete
    Part 44:final carbon parts cutting complete 1 of 4
    Part 45:final carbon parts cutting complete 2 of 4
    Part 46:nickel coated carbon parts delivery
    Part 47:carbon fiber accents part 1 of 2
    Part 48:hdd activity indicators
    Part 49:soldered motherboard power part 1 of 3
    Part 50:assembling copper fins part 1 of 4
    Part 51:copper polishing part 1 of 3
    Part 52:new fittings and rough-cut copper showcase
    Part 53:Langer returns after a year at school - PrometheusCU continues
    Part 54:Video Teaser Trailer

    This is my first real desktop mod, and it's been long in planning. Now that most of my components have arrived and some progress has been made I've decided to share what I've created so far.

    The concept behind this case is to design a simple elegant case jam packed with technology, toys, and a powerful watercooling setup.

    The idea for the design was directly inspired by the case I started with, a 10th Anniversary Lian-Li PC-a60c: *click for big*
    [​IMG] [​IMG] [​IMG]
    [​IMG]


    First I'll outline the system components I'll be using:

    Main System
    Lian-Li PC-A60C 10th Anniversary #294 of 300
    Silverstone Strider 1200W Modular ATX
    AMD Phenom X4 9850 BE Quad Core AM2 2.5GHZ
    Corsair Dominator PC2-8500 5-5-5-15 8GB (4x2GB)
    ASUS AM2+ M3N-HT Deluxe Mempipe 3-way SLI
    2x EVGA E-geForce GTX 280 SSC 648MHZ 1024MB 2.322GHZ

    Secondary System
    VIA ARTiGO Kit A1000 C7 1GHZ 1GB DDR2
    OCZ 1GB DDR2 SODIMM PC2 PC-5400 667Mhz
    Fujitsu 2.5" IDE 5400RPM 120GB
    XDX 7" VGA Touch Screen TFT LCD 1024x768

    Router/Firewall
    PCEngines ALIX.2C1 Kit 3x10/100LAN
    SparkLAN WMIA-207GN WLAN 802.11n Mini PCI
    1GB Type 6 Compact Flash

    Storage/Media
    Pioneer Slim 8X DVD+/-RW Slot Load
    Slim CD/DVD-ROM to SATA Adapter
    4x Hitachi 3.5" SATA 7200RPM 750GB
    3x LaCie Neil Poulton eSATA 7200RPM 750GB External
    Lian-Li Aluminum 50-in-1 Card Reader

    Additions
    Mini Nova USB Bluetooth Adapter
    Zalman Plus Multi Fan Controller
    Matrix Orbital GX Typhoon USB TRI-LED LCD 240x64
    2xNexxtech mini 4 Port USB Hub
    AquaComputer multiswitch USB 1.41
    AquaComputer aquaero 4.00 USB

    Air Cooling
    6xScythe Ultra Kaze 120mm x 25mm 133.60CFM
    1xScythe Kama-Flex 80mm x 25mm 34.0CFM
    9xScythe Mini Kaze Ultra 40mm x 20mm 4.86CFM

    Watercooling
    Aqua Computer Aquastream XT Ultra USB Eheim 12 V
    Feser XChanger Triple 120mm Xtreme
    D-TEK FuZion V2 Socket AM2 Waterblock
    D-TEK FuZion v2 Quad Core Mid Chamber Insert
    Mips Ram Freezer 4 Ram Waterblock Nickel Edition
    2xAquaComputer G200 waterblock for GX280
    AquaComputer Durchflusssensor (Flow Sensor)
    6xAquaComputer Rotary elbow adapter G1/4
    AquaComputer aquaero/aquastream XT temperature sensor 70 cm

    Danger Den Cooling System Fillport Black
    Primochill Primoflex Pro LRT Black 1/2IN ID 3/4IN OD Tubing
    20x Bitspower G1/4 High Flow 1/2IN Dark Nickel Plated Barb Fittings



    Here is a rough concept of the design plans: *click for big*
    [​IMG]
    Rough Designs for the front panel, top panel, and dive bay enclosure panel
    [​IMG]

    Now onto part pictures: *click for big*
    AMD Phenom 9850 BE
    [​IMG]
    Asus M3N-HT
    [​IMG] [​IMG]
    SilverStone Strider St1200 1200Watt
    [​IMG] [​IMG]
    Corsair Dominator RAM
    [​IMG] [​IMG]
    The 120mm Fans
    [​IMG]
    The MO TyphoonGX tri-colour
    [​IMG] [​IMG]
    The Linksys WIFI-n card for bypassing the emedded firewall
    [​IMG]
    I'm sorry I diddn't take any progess pics so-far but I'll be doing so from here on out.

    After a few hours with the dremel and jigsaw... then many more with a set of hand files I turned my lian-li case into the below:
    [​IMG]
     
    Last edited: 29 May 2010
    ComputerKing and Stig like this.
  2. Langer

    Langer Jesse Lang

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    The details:
    First I cut out some material from the drive bay area
    [​IMG]

    I then mounted the Alix 2c1 embedded linux firewall after installing the mini-PCI wifi-n card and the 1GB compact flash
    [​IMG]
    A cutout was made to allow space for the lan ports on the motherboard tray. Also a box was cut from the drive bay to allow for the pump to be mounted.
    [​IMG]
    I haven't yet built the pieces that will guide the airflow; but i have installed the fans that will cool the Alix board.
    [​IMG]
    1/4inch slots will be milled on the panel and dividers will be constructed to guide the air out the slots. Until then, this is how it stands.
    [​IMG]
    Here is the Pump
    [​IMG]
    [​IMG]
    And the mounting bracket put into place
    [​IMG]

    Two 120mm fan holes were cut from the top of the case
    [​IMG]
    [​IMG]

    A large rectangle was removed from the front panel to make space for the 7" touch panel LCD
    [​IMG]
    [​IMG]
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    I then built another temporary bracket to hold the PSU in place. This too will be replaced with a CNC machined bracket.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    After cutting a piece of copper plate that will 'compression' fit into place. I used double sided foam tape to afix the slot load dvd-rw.
    [​IMG]
    I then installed the slim-DVD to SATA adapter.
    [​IMG]

    The drive is then squished into place, and holds suprisingly well
    [​IMG]

    Then the pump is mounted to the bracket, this foam is also temporary and will be replaced with black neoprene
    [​IMG]

    We then come to the Pico-ITX unit that will live in the drive bay
    [​IMG]
    [​IMG]

    Here is is installed
    [​IMG]
    [​IMG]

    I then cut apart the Corsair Dominator fan assembly and made some temporary mounting brackets, the final brackets will be CNCd as well.
    [​IMG]
    [​IMG]
    [​IMG]

    The zalman fan controller that I'll be using
    [​IMG]

    Here is the fan contoller installed
    [​IMG]

    The final fan assembly and some glamour shots
    [​IMG]
    [​IMG]
    [​IMG]

    I also got a Lian-Li card reader, it will be stripped of its case by the end of this mod
    [​IMG]
    [​IMG]
    Here is the radiator I'll be using:
    [​IMG]
    [​IMG]
    The cutout I made, where it will live. I still have to make mounting brackets for it.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    This is where the hard drive bay will mount
    [​IMG]
    [​IMG]

    But first these need to be installed. Again these are only temporary, for fitting purposes, the final peices will be made from copper plate and will be CNC machined.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Now we can suspend the drive cage
    [​IMG]
    [​IMG]
    [​IMG]


    And finally we come to the below images. This is how Project PrometheusCU sits right now, waiting on delivery of some of my watercooling components.
    [​IMG]
    [​IMG]

    As it stands I'm at about 30% complete.

    Here's a list of to-do's:
    >>The CAD drawings for all the parts to be cut from copper plate are complete - meeting with machinist on Tuesday to discuss fine details and re-engineer what I've got.
    >>I've completed a number of "engineering diagrams" that will describe how to use/disassemble the case. I'm going to have these engraved into the case - to add that factory engineered look
    >>Make mounts and a grill for the 3 rad fans
    >>Fabricate the copper 'skirt' that will add 4" to the system height and elevate the rad off the ground
    >>Wait on delivery of a new AquaComputer parts as well as a few other watercooling components.
    >>Mill slots into sides of front panel to allow for air intake on front mounted 120mm case fan
    >>Mill slots into side panel to alloy for Alix air cooling exhaust.-
    >>Then it's just wiring, which in itself is going to be a massive undertaking. I've had some 18AWG ribbon wire custom manufactured for this case (which will leave me with about 1200feet of extra wire for future changes... lol). The wire will be carefully folded and guided around the case, the intent is not to hide the wire, but make it a part of the aesthetic
    >>Build controllers for and plan some kind of exotic LED light display from white LED
    >>Replace all mounting hardware with a combination of Brighton branded socket cap head machine screws and socket countersink head machine screws

    Hope you all enjoy the work... I've poured pretty much everything I have into this case - in terms of both skillsets and money.

    Please feel free to leave comments, crits, suggestions.

    Tune in soon for more!
     
    Last edited: 21 Oct 2008
  3. pksjaveed

    pksjaveed Nmodz: modding the world

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    wow now that is one overloaded case!!! nice stuff will be defenintely watching especially the pico motherboard part
     
  4. MrWizard

    MrWizard New Member

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    It almost makes me wince to see one of the beautiful cases cut up, but you're pulling it off well. This should turn out really nice in the end and you have alot of innovative features. :thumb:
     
  5. E.E.L. Ambiense

    E.E.L. Ambiense Acrylic Heretic

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    Nice, but I'd cringe at all those 40's running up front! Too much noise for not enough flow.
     
  6. IanJackson

    IanJackson Photographer & Modder

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    Ya i have to agree with E.E.L. 40mms are way to noisy for my tastes but if it works for u thats fine. why r u adding in the picos systems? hope it turns out well!!! Ace:thumb:
     
  7. Langer

    Langer Jesse Lang

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    @pksjaveed - Thanks!

    @MrWizard - Working up the courage to go at the case was a little nerve wracking; but I'm certain it'll pay off.

    @E.E.L. Ambiense - The 40mm Scythe Mini Kaze Ultra are almost completely silent... I was really amazed when I first plugged them in. The smaller fans are more for aesthetics than anything, and the bigass 133cfm fan venting out the top will be more than sufficient anyway.

    @[xXx] ãÇè_ƒr€áK- The Pico will serve two purposes - 1)a media jukebox, and 2)it will run Windows Home Server to act as a remote file server (hence the use of the embedded linux SBC)
     
  8. MrWizard

    MrWizard New Member

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    I can't wait for more on this project, just re-read through the log...lol. I'm pretty excited to see how it ends up.
     
  9. twentynine

    twentynine Can never win...

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    Very nice. I'll be looking out for this one. I have to say its very impressive how you've planned it out and made diagrams. Its inspirational actually!

    I'll be waiting for the next update!
     
  10. Burnout21

    Burnout21 Is the daddy!

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    craigbru just got owned by this project!
     
  11. MixWizard

    MixWizard New Member

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    Nice :thumb: I especially like the use of the Alix 2c1 and the Pico-ITX

    *Subscribed*
     
  12. Langer

    Langer Jesse Lang

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    @MrWizard - Thanks for the kind words, happy to hear.

    @twentynine - Updates should be pretty regular, and Thank you.

    @Burnout21 - I don't know about that, I love his Rogue - Craig's work there was a big inspiration to this project.

    @MixWizard - Thanks, tune in soon!
     
  13. wbdog206

    wbdog206 not me

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    very nice work,nice clean cuts there.
    i going to watch this one progress.
     
  14. craigbru

    craigbru Now... with more CNC!

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    Oh man... Lol...



    Now this is how you start a worklog! This is one hell of an ambitious project. I absolutely love your parts list! Regardless of case size, I love seeing hardware filling every little nook. You, my friend, are a man after my own heart. :thumb:
     
  15. Burnout21

    Burnout21 Is the daddy!

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    i had a feeling that you got ideas from Craigbru.

    tell me does the firewall ITX behind the motherboard plate link to the main system via a standard RJ45 cable, which allow the main system to connect to a wireless router.

    main system > RJ45 > firewall system > wireless > boardband connection

    if so I WANT!! lol
     
  16. Langer

    Langer Jesse Lang

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    @Burnout21 - That is exactly the plan.
    The plan is to 'tap into' the Ethernet port on the ASUS board - I'm going to solder on an additional Ethernet port on the underside of the motherboard, then I need to made another cut in the motherboard tray to allow easy access from the Alix unit to the ASUS board.
    From there I need to make a male->female extension relocating one of the ports on the Alix to the exterior of the case

    Then run it as listed below
    ASUS Board -> cat5 -> Alix port 2of3 -> pfSense -> WIFI card -> internet
    Pico Board -> cat5 -> Alix port 3of3 -> pfSense -> WIFI card -> internet
    Also, to allow LAN connection
    intertet -> cat5 -> female/male cat5 extension -> Alix port 1of3 -> pfSense -> cat5 -> ASUS/Pico

    The Alix 2c1 boards are a little pricey, but you'll never find a more versatile/secure router for the price.
    Compared to the next best option, the Soekris net 4501, you can see that it's considerably faster, and has 2x the memory.

    Alic 2c1:
    * 433 MHz AMD Geode LX800 CPU
    * 128 MB DDR DRAM
    * 3 Ethernet
    * 1 miniPCI
    * 1 serial

    Soekris net4501:
    * 133 Mhz CPU
    * 64 Mbyte SDRAM
    * 3 Ethernet
    * 1 Mini-PCI
    * 1 serial
    * 1 3.3V PCI connector.
     
    Last edited: 18 Jul 2008
  17. Burnout21

    Burnout21 Is the daddy!

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    then are you either going to use VNC or remove the CF card to access the tiny tiny linux hidden within, lol


    oh and sir how did you come to void the warrenty upon your motherboard, 'well i took my trusty soldering iron out and well....' i see, good bye!
     
  18. Langer

    Langer Jesse Lang

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    Actually...
    I'm going to butcher this little guy - see image below - and solder it up to a male plug. The pico unit will then serve to communicate with the Alix board via USB->Serial.

    [​IMG]


    As for the warranty - as my Father always said: "Warranties are for people who don't know what they are doing" .... so I'm pretty much screwed.
     
  19. MrWizard

    MrWizard New Member

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    Wow, this is a super ambitious project, but I'm loving it more and more with every new update! Keep it up Langer, can't wait to see what you've got for us next.
     
  20. x06jsp

    x06jsp da ginger monkey!!!!

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    looks great mod on :thumb:
     

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