Case Mod - In Progress Project : Rugged case, (complete)

Hello guys!

I started a little project.
Low budget and practical case for heavy duty. (with handmade lucid cooling, but it's secret now)

My previous mod (last war) work since 2008, hardware since 2006... .
Very old PC, performance about 4.5Gflops.


I have a very old case for mod.

I have four side panels.
But only one match.

Not problem, it will used to create front panel, HDD rack and second side panel.


At fist, create HDD rack.
Cutting with jigsaw.

Drilling.

Riveting.

Ta-daaa, we have rack for four HDD.


That's all for today.

 

Some steps have been skipped on photo.
Ask me, if you have any questions.

Yesterday I have decided two important things.
First: case must be inverted.
Second: 3x120mm fan must be on font panel.

Next cutting front panel.

Cutting case.

And top (bottom in the past).

 

I has modified fan cables and fan controller earlier.

Case fan.


Comparison with 300W PSU.


Fan cables.


Fan connectors.


A few hours later.


In past transistors was very hot.


Now transistor as ice. )))


My workspace.

 

Ha ha, I have an old case just like yours that I was thinking of chopping up too. I'm interested to see where you take yours... Keep modding!

 

Will see )

Yep!

 

Next step: hole for tubing and front grill.
Took four washers M22.


Riveting to case.


And... don't know how it's called...


Cutting three grills from ventilation system.


Nuked front panel.


With fans.


With dust filter.


And with grill.

 

NIce work m8.

But why did you cut those grills, you should use it in one piece.

 

Thanks!

And obtain dead zone in airflow?
What for?

I have metal grills only 15x15cm .
In shops the are plastic grills as a rule.

 

my bad. I thought that plastic grills were one piece.

 

yeah, I was thinking the same thing until I realized the scrap edges in the bottom of the picture were the 4 ends that were cut off


I like the resourcefulness of this mod...

 

This is only warm-up.

 

Today i've been starting waterblock.

Cooper stick. Diameter 60mm.


Cutting... cutting... cutting... about 40 minutes. (slice 12mm)


And sanding.


Perfect surface.


Tomorrow will be a big day... .

 

That is one big piece of copper! Where did you find that? Looks like a lot of work just to cut a slice - good job!

 

Four years ago in one metal shop.
They have 2.2m slick, it's very expansive for me... and... for what me 70 kg of copper?
But i have urged manager to cut off piece for me... it was difficult.
It is impossible to buy stainless steel, aluminum, brass or copper in our city... .
That? That is miracle.

Copper is a very tough metal, difficult to cutting.

 

Today work.

Waterblock base.




I want a milling machine... .

Stainless steel 2mm.


Preparing to soldering.


Tomorrow parts will be soldered.

 

nice job, do you plan any lapping on that wb once finished?

 

Soldering in progress






The result.


And after polishing.



Hmmm... any questions?

 

very impressive! did you test it for leaks yet?
Also, does the top of the copper touch the bottom of the stainless steel (i.e. does all of the water have to flow through the copper block, or does some water flow over the top)?

 

Thanks!

Sorry, i am not understood a question... .
What means "lapping"?

Thanks. )

Yes, all is ok.

About 0.1-0.5mm between them.


Next will be reservoir.
And test on real system.

 

you answered me with that picture! absolutely impressive!