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Scratch Build – In Progress [Scratch Build] Project BlackBird

Discussion in 'Project Logs' started by sagar, 22 Oct 2015.

  1. sagar

    sagar Member

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    Update 10

    The composite material is here, it is a composite of PVC sandwiched between aluminum.

    [​IMG]

    The color of the sheet is golden which i would be painting

    [​IMG]


    Also just wanted to say that i wont be able to update or work on the mod for the next 5 days due to a festival.

    Till then Peace
     
  2. sagar

    sagar Member

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    What do you guys think
    Air cooling or Water cooling ?

    Would be able to fit 2x360 rads but if I do water I'll do only one, and if I do air cooling I'll have to use an ITX cooler that is a low profile one.

    Would go this way if I get enough cash
     
  3. sagar

    sagar Member

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    Update 11

    Finally back on the project.
    Sorry for the delay was caught up on some work


    Here it is, the cutting of the side panels and the support structures

    The full size
    [​IMG]

    Cut into an approximate shape using a grinder
    [​IMG]

    The support triangles cut
    [​IMG]


    Just a hell lot of dust and dirt all around me as well as on me :wallbash:
    [​IMG]


    Will finish these in the next couple of days.


    Had in mind that i would complete this project by December but due to a change in the college exam schedule wont we able to progress at a speed that i wanted
     
  4. sagar

    sagar Member

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    Crap, today I noticed bends in my aluminum angles which were going to act as support for the whole case.

    Need go find another way out.

    Next update will be after mid December.

    Till then peace
     
  5. sagar

    sagar Member

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    Update 12

    So guys,
    I'm back again at the case.
    had a long break but now I'll try to complete this in a week or so.

    The break caused me to change the whole case look. (Thanks to some of the modders)

    Cut and filed the side legs of the case.
    [​IMG]

    [​IMG]

    From now on will be eye-balling everything rather than depending on a 3D sketch.

    More pics to come soon :thumb:
     
  6. sagar

    sagar Member

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    Update 13

    Today got a wooden frame/jig made up so i could get the sides perfectly squared for the case

    Frame with the metal angles
    [​IMG]

    Test fitting an old m-atx mobo
    [​IMG]

    Testing the power supply and HDD tray mounting positions
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    Got the HDD tray from the old case as well
    [​IMG]

    Had these extra side panels from the old case which i cut up. Would use these as the double-mid plate for the case
    [​IMG]
    [​IMG]



    Till tomorrow then, PEACE :thumb:
     
  7. sagar

    sagar Member

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    Update 14

    Got the aluminum angled rods cut to fit each other

    [​IMG]

    [​IMG]

    A preview on the case

    [​IMG]

    The support pieces for the frame

    [​IMG]

    Checking the fit of the support

    [​IMG]

    Till tomorrow then, PEACE :thumb:
     
  8. PH0ENIX

    PH0ENIX New Member

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    where you from?delhi??
    nice mod but the case design looks little plain.try pimping it up
     
  9. sagar

    sagar Member

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    Update 15

    Mocking up the side panel on a piece of paper.
    PS the giant cutout in the middle is for GLASS or ACRYLIC.

    [​IMG]

    Cut the paper and transferred the design on the PVC/aluminum sheet I have

    [​IMG]

    [​IMG]



    I'm from Gujarat, and yes the case might look plain right now but all the panels I'm adding will make it pop

    Till tomorrow then, PEACE :thumb:
     
  10. sagar

    sagar Member

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    Update 16

    Didn't get much done in the last 3 days, was waiting to get my hands on a cutter.

    Finally borrowed it and roughly cut out the outlines for the side panel.
    Tomorrow is gonna be a tiresome day as will have to cut and smooth out the edges.

    [​IMG]

    Till then, PEACE :thumb:
     
  11. sagar

    sagar Member

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    Update 17

    Got the side panels trimmed today.
    Will be sanding them tomorrow as my old sandpaper isn't effective anymore.

    [​IMG]

    This is how it will look assembled

    [​IMG]

    [​IMG]

    Till then, PEACE :thumb:
     
  12. sagar

    sagar Member

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    Update 18

    It took me 2 days to get the side panels nice, flat and almost smooth.
    Took a lot of filing and sanding along with elbow grease.

    [​IMG]

    Here id what it will look like on the case

    [​IMG]

    [​IMG]

    Till then, PEACE :thumb:
     
  13. sagar

    sagar Member

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    Update 19

    Used tape to stick all the angles to the side panels, which were also held together by tape

    [​IMG]

    Also got my hands on a drill today.
    Drilled out all the holes and screwed them

    [​IMG]

    [​IMG]

    [​IMG]

    This wood is going to act as a base for the case. Drilled out holes for the hinges that would be connected to the sides.

    [​IMG]

    This is how the case rests right now with the sides attached.
    Will be changing the way they sit tomorrow.

    [​IMG]

    [​IMG]

    Till then, PEACE :thumb:
     
  14. sagar

    sagar Member

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    Update 20

    Took me a few days to design and build the top covering of the case.
    Finally came up with this design. Cut the panels in the shape and mocked it up.

    [​IMG]

    Drilled holes in the frame to mount these panels.

    [​IMG]

    The idea earlier was to leave no space between the flaps.

    [​IMG]

    Later changed the idea and put a few spacers between the panels to give it an elevated view which makes it look cool but also increases thre air flow of the case

    [​IMG]

    [​IMG]

    The project is almost 70% complete.

    Till then, PEACE :thumb:
     
  15. sagar

    sagar Member

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    Update 21

    Had to take some time to figure out the stand/legs for the case

    Found my old aluminum angles which were cut, marked some lines and started cutting

    [​IMG]

    Left unfinished | Right finished

    [​IMG]

    Got all the legs cut and finished

    [​IMG]

    Marked the lines where the feet were to be located

    [​IMG]

    Stuck the legs using tape just for mock up

    [​IMG]

    With the scavenged panels from my disassembled case, which is going to act as the main base of the case

    [​IMG]

    Test fit the mobo and psu into the case earlier but still needed an extra few mm of space for perfect fit so added 2 pieces of wood to rise the top

    [​IMG]

    Next steps are gonna be attaching the feet to the case using screws, painting, getting the mid panels cut and then finally mounting the hardware inside.

    Till then, PEACE :thumb:
     
  16. sagar

    sagar Member

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    Update 22

    So guys back at it again.
    Finally got time to work on the case again.

    Made some major changes on the case and hardware.
    Got a cooler master hyper 103 instead if a low profile cooler so had to modify the case for it.
    Decided to remove the PSU from the case and mount it to the bottom.

    Decreased the width if the case and cut new bottom panel for it.
    [​IMG]

    Traced the cutout fot the IO
    [​IMG]

    [​IMG]

    Working on the top panel yet again using the screwdriver as a chisel
    [​IMG]

    [​IMG]

    This is how i think im gonna mount the base of the case and the frame.
    [​IMG]

    Making the mounts and supports for the base joint
    [​IMG]

    The next update will mostly cover the base.


    Till then, Peace :thumb:
     
  17. sagar

    sagar Member

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    Update 23

    Today's work had no major progress because most of it went in vain.

    Worked on making the back panel for the case

    [​IMG]

    Also worked on the support connecting the base and case because the last one was a few degrees off and hence lead to blockage of the IO access panel

    [​IMG]

    [​IMG]

    [​IMG]

    Here the new support structures added.

    [​IMG]

    [​IMG]

    Had to work on the top panel again as I forgot to take in consideration the bend in the frame and now have to cut them down to fit inside the frame rather than outside it.

    [​IMG]

    Till then, Peace :thumb:
     
  18. sagar

    sagar Member

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    Update 24

    Had been working since Friday.
    Got a lot of work done

    First a previous case progress pic.

    [​IMG]

    Started working with the back panel of the case. Straightened it out and fixed everything to length.

    [​IMG]

    [​IMG]

    Next started with filling the holes that are of no use now that the design has changed. Used m-seal to cover them up.

    [​IMG]

    [​IMG]

    Next sanded them up and got their surface prepped.

    [​IMG]

    Next worked on removing excess material from the front area of the case to house the front panel.

    [​IMG]

    Next started working on the front panel. Had to remove a lot of material from the center and then had to break it in such a way that the panel didn't break. But before i broke it I sanded the surface for the paint for later on.

    [​IMG]

    Bent it and made a jig for the same.

    [​IMG]


    [​IMG]

    The next step was to fill it with m-seal so that it can be supported and i could get that line in the middle like it was one piece. After applying m-seal had to let it dry fro about 2-3 hours. Then I started sanding. Took me about 1.5 hours to get it sanded for the perfect line in the middle. (*sorry for the bad picture)

    [​IMG]

    [​IMG]

    Next had to cut support structure to support or mount the front panel and also to fill the gap between the top and front panels. This will also act as a housing for the power and reset switches.

    [​IMG]

    [​IMG]

    [​IMG]

    Attached everything to the case using tape as don't have a drill at the time.

    [​IMG]

    Now most of the case is done. The only things remaining are
    1) mid panel for the mobo and hard drives
    2) Working on the base
    3) Paint

    That's it, a few more days and it would be done.

    Till then, Peace :thumb:
     
  19. sagar

    sagar Member

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    Update 25

    I had been waiting on the drill for the last few days. Finally got it.

    First thing i did was drill and screw the top to mount the top air vents.

    [​IMG]

    Next drilled and screwed in the back for the back panel.

    [​IMG]

    Then I stared on drilling the holes for mounting the bottom support brackets and the base.

    [​IMG]

    [​IMG]

    Later mixed some epoxy putty to mount the front of the case to the front support frame.

    [​IMG]

    Added some tape to help remove the epoxy.

    [​IMG]

    [​IMG]

    [​IMG]

    Also scratched the surface of the front panel to help in better adhesion, but unfortunately it didn't hold up.

    [​IMG]

    Here it is mounted to the base and standing tall.

    [​IMG]

    [​IMG]

    Till then, Peace :thumb:
     
  20. sagar

    sagar Member

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    Update 26

    Got a few bits and bobs done today.

    Mixed up some epoxy and filled the gap between the top and the front panel connector and sanded it. This is the same short bot of panel which will hold the power button.

    [​IMG]

    [​IMG]

    Test of the whole assembled case. Had more pics but the shitty cam in my new phone messed it up.
    setup 1 with the slanted base.
    [​IMG]

    [​IMG]

    Setup 2 with the base flat. (my mom insists that I go with this setup)
    [​IMG]

    What does the community think of the setups, which would be better.
     

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