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Case Mod - In Progress Thermaltake Level 10GT Mod - COD MW3 Minigun Video

Discussion in 'Project Logs' started by Boddaker, 24 Oct 2011.

  1. Boddaker

    Boddaker Still hangin around

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    Hey everyone, I've been working on a new project for the last couple months. After TRON, I was going to take a break, but it just wasn't in the cards lol. When Thermaltake announced their contest involving the Level 10 GT, I thought it would be fun so I entered. The contest is nearing the finish now, and I think I'm the only one left who's not done lol. I should be wrapping it up within the week tho. For some reason I thought the contest was forum-specific, which is why I haven't posted my log on here until now. I just noticed Dmcgrath and Mods-Cases on here, so I guess it's not against the rules. :)

    Ok so let's get caught up:

    August 19
    I knew it would be a challenge to come up with an idea that would transform this unique case into something different. Even though it has been done a few times before, I ultimately settled on a military theme. I'm hoping I can put a fresh twist on it and be able to show something new. Hence my specific focus on Call of Duty: Modern Warfare 3.

    After studying the case and its features, I decided to play off its compartmentalized design, with each section serving a different purpose: Ammo box, first aid kit, mini gun with magazines. Here's a quick photoshopped image of my concept:
    [​IMG]

    Should I post it all up now, or do a few posts a day until it's up to date?
     
    3lusive and yassarikhan786 like this.
  2. -Jv-

    -Jv- New Member

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    I want it all and I want it now. :D I'm looking forward to this build already !
     
  3. Marcos_Viegas

    Marcos_Viegas Member

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    Amazing concept, I will follow the project to see it stay that way in the end!

    Congratulations on your idea! :thumb:
     
  4. C4B12

    C4B12 Minimalistic PC's

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    Cold Winter | by C4B12

    Im so sorry, was gonna do a thread and was reading this at the same time and posted here. So so sorry.
     
    Last edited: 25 Oct 2011
  5. rieh

    rieh New Member

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    Nice concept. I wonder... What if you rigged a motor to the minigun so it would spin? Perhaps a fan motor, so it would already have a direct interface with the mobo...

    This looks like it's going to be an awesome project. Bookmarked.
    Also, congrats on your Photoshop skills. xD
     
  6. Boddaker

    Boddaker Still hangin around

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    Thanks guys! Ok, I'll post all the updates in a minute here. There's only about 5 or six posts total anyways lol.

    @ rieh, Yes I plan to hook it up to a servo and make it spin. We'll see if I have enough time. :)
     
  7. Boddaker

    Boddaker Still hangin around

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    September 6

    First thing I'm going to do is work on the forward minigun. I started off making the two round barrel holders out of scrap pine. I cut two 6" diameter circles and chamfered the edges. Then I set about marking six 1" holes evenly spaced around the circle, and drilled them out with a spade bit, clamping both pieces in the vise to ensure uniformity.
    [​IMG]

    I had drilled a hole in the centers and bolted them together to make sure they didn't move during all the hole drilling. This also enabled me to fix the pieces in my drill press and sand the edges to a perfect roundness.
    [​IMG]

    Once the center bolt was no longer needed, I took my 2" hole saw bit and drilled out the center.
    [​IMG]

    Next up is the 6 barrels. For these I'm using basic schedule 40 PVC pipe. I cut six 12" pieces and rounded the ends a bit.
    [​IMG]

    Stuck them through all the holes, spaced the holders out a bit and there you have it.
    [​IMG]

    Test fitting the barrel assembly into the case. It's a snug fit, but I'll be removing the hard drive mounting surfaces later so I'm not too concerned there.
    [​IMG]

    [​IMG]

    Trying different depths to see where it looks best. Don't want the minigun protruding out too far.
    [​IMG]

    Next I'll be making a back plate to secure the barrels, and mounting it into the case.
     
  8. Boddaker

    Boddaker Still hangin around

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    September 11


    So I decided to jump right in and get the magazines done next. I first made a paper template to get the size and shape of the magazine extensions.
    [​IMG]

    I grabbed some scrap acrylic and cut out all the pieces to make five magazine extensions.
    [​IMG]

    I stacked them up and filed the edges down simultaneously to ensure uniformity (and save time). Here is one magazine loosely assembled for a test fit.
    [​IMG]

    Here it is next to one of the hard drive caddies.
    [​IMG]

    I'll remove the spring loaded handle underneath and cut the top part down so the magazine will slide right onto it. Then I'll glue it into place.
     
  9. Boddaker

    Boddaker Still hangin around

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    September 19

    I took the hard drive trays and notched them so the magazine extensions would slide onto them.
    [​IMG]

    [​IMG]

    Then I used some plastic weld to glue them on.
    [​IMG]

    Stuck them into the slots and realized that in order to get them to snap into place again, I had to round the corners of the slots a bit to fit the curve of the magazines. Didn't take much tho.
    [​IMG]

    Next I brought out the styrene for some quick and basic detail.
    [​IMG]

    Now they're looking more like rifle magazines. :)
    [​IMG]

    All five mags done, and back into the slots.
    [​IMG]

    Next step was to fill in any gaps and rough edges with bondo, and round the corners. Here's a before and after shot.
    [​IMG]

    Shot the trays with a coat of primer to see how they look.
    [​IMG]

    With the mags pretty much done, I started work on the AT-4 handle up top. I'm using an ABS 2" pipe and some couplers for this. It's kinda hard to see in the pic, but I cut a slot in the pipe to accept the metal case handle.
    [​IMG]

    It's a nice snug fit. It's not centered because the front of the handle extends out more due to the front panel of the case.
    [​IMG]

    [​IMG]

    And the obligatory "on-the-case" pic to finish off the update.
    [​IMG]

    I still have to figure out how to secure the pipe onto the handle. I can't glue it on permanently unless I drill holes in the top to access the screws that fasten the handle onto the case. I'd like to make it so just snaps in place, with a quick-disconnect so it can be removed and put into use in case a Panzer tank happens to crash through the wall at the next lan party. :p
     
  10. Boddaker

    Boddaker Still hangin around

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    September 22

    Work continues on the AT-4 Handle. I figured out how to fasten it to the metal handle frame. I decided to create four tabs that the tube could rest on. I simply used my hack saw to make a few cuts in the frame, and bent them down.
    [​IMG]

    Here's a close up of one end,
    [​IMG]

    and the other. The curve isn't perfect, as I just used a pair of pliers to bend them. 0-0
    [​IMG]

    I then drilled holes and tapped the tube to accept some 6-32 thumb screws. I think I have some black ones somewhere....
    [​IMG]

    For the ends, I found some ABS reducers that actually have the octagon shape to match the ends of the AT-4. :D
    I just needed to remove the flared part.
    [​IMG]
     
  11. Boddaker

    Boddaker Still hangin around

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    September 25

    I continued with making the back panel, using some scrap black anodized aluminum sheet. I used one of the wood pieces as a template.
    [​IMG]

    To attach the PVC barrels, I got these PVC plugs.
    [​IMG]

    They will sandwich the aluminum plate between the plug and the ends of the barrels. I'll glue them in later.
    [​IMG]

    Then I added a rod in the center and secured it to the panel with a collar. This is where the pulley will go that will connect to the servo.
    [​IMG]

    I made up a new back panel for the former 5 1/4 bay area,
    [​IMG]

    ...as well as a new bottom panel.
    [​IMG]

    Here's a shot of the new panels in the case.
    [​IMG]

    Next step was to figure out where the minigun was going to stick through the front bezel, and make a square hole into a round one.
    [​IMG]

    Using some scrap 1/8" acrylic, I made a couple pieces and glued them in.
    [​IMG]

    I temporarily assembled the gun and placed it in for a test fit. But in order to do that, I had to transfer the center of the front circle to the back panel and drill a hole for the rod/drive shaft so it sat level.
    [​IMG]

    Once I had the minigun centered, I could mark the bottom panel to attach some rollers that will support the forward weight of the minigun. For the rollers, I'm cannibalizing a couple old drawer slides I had lying around.
    [​IMG]

    After filing them down, I mounted them to the bottom panel with some pop rivets.
    [​IMG]

    With everything back in place, you can see how the minigun is supported by these rollers.
    [​IMG]

    Finally a wider shot of the whole assembly. Somewhere along the way, I sanded and primed the barrels and wood pieces.
    [​IMG]

    Next I'll mount the servo, and maybe even take her out for a spin. I'm concerned that the servo I have won't be strong enough to get the minigun rotating, as it is fairly hefty. Hopefully, the rollers will alleviate some of that weight, and it will work as planned. Otherwise I'll have to invest in a beefier motor.
     
  12. Boddaker

    Boddaker Still hangin around

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    October 1

    Scored some goodies at the local army surplus store. Got a first aid box, fat ammo can, and camo paint.
    [​IMG]

    They actually had the exact color that matched the ammo can. :)
    [​IMG]

    The ammo can was just a bit shorter than the stock window section,
    [​IMG]

    However, upon removing that piece, it turns out that it will still look ok.
    [​IMG]

    I lined up the ammo box to the back corner and outer edge, and will cover up any open areas with a trim piece later.
    [​IMG]

    So with everything planned and measured out, I started hacking it up. First the jig saw.
    [​IMG]

    Then I finished up with the Dremel.
    [​IMG]

    After much thought, I decided that the front part of the ammo can will open up with the door panel. So thed section I just cut off will be fastened to the door, like so.
    [​IMG]

    The easiest way to secure it was to create tabs in the door.
    [​IMG]

    The tabs will sit inside the ammo box, and it will be fastened with pop rivets.
    [​IMG]

    Next was to cut off the top part of the ammo box, that will reside on the top of the case. I actually had the forethought to include mounting tabs on the piece. :)
    [​IMG]

    With the tabs bent, I could set it onto the case for a fit. I put the door on with the other part to make sure they lined up before marking the mounting holes.
    [​IMG]

    The lid still fits! This is a good sign.
    [​IMG]

    The lid will open from the back. You'll notice I had to make room for the door hinge as well.
    [​IMG]

    A close up shot of the top section, pop riveted in place.
    [​IMG]

    And the back side riveted.
    [​IMG]

    And one more with the lid on.
    [​IMG]

    Next step was to cut the top bezel to fit around the ammo box.
    [​IMG]

    Fits nicely. Now I know how big to make the trim piece to cover the gaps.
    [​IMG]

    A piece of 1/8" acrylic should do the trick.
    [​IMG]

    I'll round the edges on the trim piece a bit and maybe add some dome rivet heads to give it more of a beefy look. Once all painted it should look pretty cool.

    I know I'm covering up a good portion of the exhaust fan with the trim piece, which would limit its airflow. So I'll replace the 200mm one with two 120mm (or 140mm) fans so they fit within the shape of the ammo box.
     
  13. Boddaker

    Boddaker Still hangin around

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    October 4

    Moving along to the first aid box...

    Upon removing the lid and placing it onto the lower frame, it's almost a perfect fit.
    [​IMG]

    I'll keep one of the latches, but the rest won't be needed because I'll be adding some hinges to the back side.
    [​IMG]

    I've got plans for this first aid box, and they don't include the door-mounted 230mm fan. Sorry!
    [​IMG]

    The honeycomb grill and dust filter also got the axe.
    [​IMG]

    Back on the door. Now about them hinges...
    [​IMG]

    This back side of the frame is too flimsy to mount hinges, especially with the dust filter slot there, so a piece of 1/4" acrylic was cut to size...
    [​IMG]

    ...and glued on to add some rigidity.
    [​IMG]

    Now the hinges can be mounted.
    [​IMG]

    I salvaged one of the latches from the box.
    [​IMG]

    Using the lid as a guide, I epoxied the latch to the frame.
    [​IMG]

    I let it set up overnight, and now it keeps the door closed tightly.
    [​IMG]
     
  14. Boddaker

    Boddaker Still hangin around

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    October 10

    Got the main box glued together, using 1/8" scrap acrylic.
    [​IMG]

    set it into the door panel for fit.
    [​IMG]

    I set the depth of the box, and taped it to the outer frame to prepare for gluing. I threw in a spare psu to make sure I wasn't encroaching into its space.
    [​IMG]

    Well, I figured if I was going to have emergency energy drinks in here, they better damn well be cold! So I ordered one of these beverage cooler/warmers from Xoxide, which will be integrated into the box. :)
    [​IMG]

    Upon removing the bottom plate, I find that all it is, is a TEC with heat-sink and a small fan. Also has a small switch that changes polarity of the tec so you can have either cold or warm beverages.
    [​IMG]

    Everything out of its casing.
    [​IMG]

    No problem incorporating the plate into the bottom of the box. Just make a hole...
    [​IMG]

    ...like so. Two mounting screws go right through the tec plate and into the heat sink, which was already tapped for me. :)
    [​IMG]

    I had to remove three fins from the heat sink so it would fit through the door panel.
    [​IMG]

    So with that taken care of, I proceeded to the painting phase. Sanded the box inside and out, primed, wet-sanded, then painted. This is by no means BOBDBONE quality, but it being based off an ammo can, I think I'm granted a little leniency here lol.
    [​IMG]

    Repainted the lid to match the ammo can.
    [​IMG]

    I had taped off the cross decal so I wouldn't have to peel it off. Here you can see me screwing up the white lettering lol. I really should have used a small roller or detail brush.
    [​IMG]

    Doesn't look too bad, after some touch up.
    [​IMG]

    I painted the inside gloss white, as a stark contrast from the outside, and because it goes with the first aid theme.
    [​IMG]

    A close up of the TEC plate. That small hole is where the switch will go.
    [​IMG]

    Stocked with a few necessities I had on hand.
    [​IMG]

    I also took care of some other parts painting today. Got the front bezel painted, as well as a few other panels.
    [​IMG]

    Here's a wide shot of the side panel.
    [​IMG]

    Angle shot with the top and front. You'll notice I added a mottled effect to the paint, because it was simply too clean. I'll toy with distressing a bit later to add more realism to it.
    [​IMG]

    And finally a back shot. I still have to add some stenciling to the ammo can, and maybe some other military type markings. But it's coming together!
    [​IMG]
     
  15. Boddaker

    Boddaker Still hangin around

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    October 24

    Nvidia was kind enough to provide a killer swag bag to all Geforce LAN 6 attendees last weekend. Along with a shirt, free game codes, and a military canteen style water bottle, it also included this mini first aid kit packaged in a nice camo pouch. A perfect addition to my box! :D It has all the necessities a LAN gamer needs.
    [​IMG]

    I will be mounting this on the inside of the door, via velcro strips. A very simple installation, just peel and stick!
    [​IMG]

    [​IMG]

    Done.
    [​IMG]

    [​IMG]

    A final test to make sure the door still closes fully.
    [​IMG]

    Next thing was to add an elastic strap inside for the beverage can. Don't want anything spilling during transport! Another simple installation, just a couple white rivets on both ends to secure it to the back of the box.
    [​IMG]

    Done.
    [​IMG]

    Can in place. I mounted it just high enough so it would hold the can, but low enough that it would be easy to grab and pull out.
    [​IMG]


    Ok, now we move on to the ammo can. I needed to add some information back onto it, since I cut the original lettering off (was on the opposite side of the ammo can). I typed the info and printed it out to size, then taped it over the masked area, and proceeded to cut each piece out with an xacto knife.
    [​IMG]

    Here's a shot of the tape with the cuts. Just need to remove the lettering parts.
    [​IMG]

    Here's the door all masked off and ready to spray.
    [​IMG]

    I used some yellow marking paint I had in the cupboard. It's the same stuff Cal-Trans uses to mark the roads.
    [​IMG]

    Unmasking...
    [​IMG]

    And done. Came out nice! Maybe too nice... :s
    [​IMG]


    More little things. This is the trim piece that goes around the top of the ammo can to hide the gap in the top panel.
    [​IMG]

    I grabbed some old hex head machine screws and cut off the heads. Here I'm using JB Weld to stick them to the trim piece.
    [​IMG]

    Close up of one of the heads. Once cured, I'll spray some primer on it, then paint, and finally glue it on.
    [​IMG]

    I also continued work on the AT-4. Got the ends cut and ready to be glued on, using some ABS specific glue.
    [​IMG]

    I neglected to take a shot of the ends glued on before applying some Plasti-Paste to fill in the area behind the ends.
    [​IMG]

    Tonight I'll be sanding those areas smooth, hitting them with a skin coat of bondo, then I'll start adding more detail to the rest of the AT-4 before priming the entire thing. I should be able to finish that up in the next day or so, then I can finish off the minigun and that should be it! Getting real close now.

    And now we're caught up! So it's back in the garage for me... :)
     
  16. BOBDBONE

    BOBDBONE Owner at BS Mods

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    Wow you got a lot done in one day.:D
     
  17. Fuganater

    Fuganater New Member

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    You are a god...
     
  18. -Jv-

    -Jv- New Member

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    Oh my god, this looks freaking amazing !
     
  19. Boddaker

    Boddaker Still hangin around

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    Ok, an update:

    Got the 140mm fans mounted inside the ammo can. I had to remove some areas of the top panel, then add in a new piece of sheet metal for the fans to mount to.
    [​IMG]

    With the door on...
    [​IMG]

    And with the lid semi closed.
    [​IMG]

    I also got more work done on the minigun.. Painted the gun barrels and made new rings out of acrylic. The wooden ones I did a while ago weren't perfectly round, so the minignun wobbled as it was turning. So I had to break down and get a couple parts laser cut. Now it turns nicely, and the servo shouldn't have any problems rotating it!
    [​IMG]

    Still gotta finish up some small trim pieces, and the servo mounting. Then I think i can call this thing done! :D
     
    David likes this.
  20. David

    David Take my advice — I’m not using it.

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    Great job, and I love the first aid kit! :D
     

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