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Scratch Build – In Progress Tribal HTPC - UPDATE 12: SPONSORS!! Koolance and DangerDen

Discussion in 'Project Logs' started by Fozzy, 31 May 2007.

  1. Fozzy

    Fozzy What's a Dremel?

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    Today I've brought you a HUGE update (at least for me) Really this should have been three separate updates but I didn't have time.

    So when we last left off the case looked like this
    [​IMG]

    I had completed all of the cuts and I was ready to start bending. Which brings us to this section of photos
    [​IMG]
    [​IMG]
    As you can see I left small 1/2 inch tabs that will end up becoming mounting points for the side panels. These were crucial as I wanted to cut down on case size by not having to add framing.
    [​IMG]
    This image shows the tabs lined up and clamped to the bending brake.
    [​IMG]
    Another angle
    [​IMG]
    And this is the first set of tabs completed.
    If we skip ahead a few bends (the rest of the tabs) we get to the more interesting part of this update
    [​IMG]
    The front, or at least the back of the front. After I completed this bend I ran into problems. Just check out this next picture.
    [​IMG]
    Due to the proximity of the grill to the bend, my brake was unable to grip the metal and the piece slipped out giving me a crooked bend. What you see here is the result of two hours of me beating on it with a hammer, trying to get it straight. This plan ultimately failed.
    [​IMG]
    Skipping ahead a little more we get to the thread riveting.
    [​IMG]
    Basically this is a hollow rivet with threads around it so when you secure the "rivet" in place it leaves a permanent "nut". Much like tapping out metal only a little sturdier since you are adding metal instead of removing it.
    [​IMG]
    Skipping ahead to the end we have a fully bent case. Some of you may be wondering what happened to the back panel at this point and it turns out my only solution was to cut off the old one and re-rivet a new one on in it's place.
    [​IMG]
    This is actually the second attempt at the new panel since the first one was made out of thicker aluminum which wouldn't bend in my break.
    [​IMG]
    The PSU fits : )
    [​IMG]
    Almost...but this is a very easy fix which I will get to later.
    [​IMG]
    and the rest are some pictures for your viewing pleasure.
    [​IMG]
    [​IMG]
     
  2. HourBeforeDawn

    HourBeforeDawn a.k.a KazeModz

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    not bad, ya I have ran into similar issues sotimes take some grip tape and putting it onto your break can help it take a better bite from the metal slipping.

    But its looking great.

    Oh also what can help with Aluminum is scoring it, take a razer blade and score a light cut in the aluminum on where you want to bend it and that will help bend the aluminum easier but dont go to deep or it will break the aluminum instead of bending it.
     
  3. Fozzy

    Fozzy What's a Dremel?

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    Yea It's ok now. As long as I bend the aluminum before I cut it or make sure the cuts are 3/4 inch away then there isn't any problems. Wouldn't the grip tape scratch the aluminum?
     
  4. Brett89

    Brett89 Minimodder

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    Wow, i'm loving the custom metalwork, looks awesome. Nice bends too, I like how it's one piece. Keep it up!
     
  5. HourBeforeDawn

    HourBeforeDawn a.k.a KazeModz

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    well a heavy grit would but a fine grit wouldnt as much compared to the scratches that are already there, good sanding and polishing afterwards would clear all that up.
     
  6. Fozzy

    Fozzy What's a Dremel?

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    Ohh ok. Yea the scratches that are there are real light. they're just from the scrollsaw
     
  7. Fozzy

    Fozzy What's a Dremel?

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    Haha thanks. Technically it's two now since I had to redo the back panel.
     
  8. Cheapskate

    Cheapskate Insane? or just stupid?

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    Nut riveter...(sounds painful.)
    Where did you get this? It may be something I can use. -Not in a painful way!
     
  9. Fozzy

    Fozzy What's a Dremel?

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  10. ComputerKing

    ComputerKing <img src="http://forums.bit-tech.net/images/smilie

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    That's so nice work! that holes make the case look great! every thing is nice.. you must fix that PSU :)
     
  11. Fozzy

    Fozzy What's a Dremel?

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    Thanks I like them a lot too. I'm thinking of ways to incorporate more of that type of grill into the case but I don't want to overdo it. And don't worry the PSU is on the list
     
  12. Evenge

    Evenge Minimodder

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    Hey nice cuts and bends! :dremel:

    Oh and btw, I do care about your work.
     
  13. Fozzy

    Fozzy What's a Dremel?

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    Haha Thank you man. It's just getting harder and harder to maintain a good project log when there is so much good work happening out there
     
  14. Cheapskate

    Cheapskate Insane? or just stupid?

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  15. TGH-odin

    TGH-odin Swedish Modder

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    Sweeet, that alu-bending work is awesome, truly!:thumb:
     
  16. HourBeforeDawn

    HourBeforeDawn a.k.a KazeModz

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    well it needs to be long like that so you can offset the leverage so that it takes less work on your part to pop the rivets, if the handles were shorter it would be a lot harder to do it, you could always get a mini air compressor and get an air rivet gun, those are a little smaller but not by much.
     
  17. Cheapskate

    Cheapskate Insane? or just stupid?

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    I was looking for something that I could hide within 1/4" plexi. Thread inserts are looking like my best option.
    -Sorry Fozzy, (for hijacking the thread.)
     
  18. Fozzy

    Fozzy What's a Dremel?

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    Thanks Man!

    Haha no problem. I'm not sure exactly what you're looking for but maybe I can shed some light. Nut rivets handle up to 1/4 inch material or at least the ones that I have do so they would work with 1/4inch plexi Although I would countersink them on both sides of the hole for a little extra grit. Also they are very easy to file down to size. I haven't filed mine yet because I want to make sure I have as much grip as I need then I'll take off the extra when everything is fitted. If you're talking about the size of the riveting tool, I know that tribal overkill uses thread serts but hits them with a hammer rather than using the tool. I'm not as precise so I prefer using the hand tool over beating on my work with a hammer.
     
  19. HourBeforeDawn

    HourBeforeDawn a.k.a KazeModz

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    Well not to take away from the thread but when it comes to pop riveting plexi you have a greater chance of cracking the plexi, what I recommend is adding a washer to both sides so that it distributes the pressure of the rivet more evenly to help prevent possible cracking. Its what I have done on my Late Model (Race Care) and computers I have worked on in the past, it seems to work the best that way.

    Oh and all this custom case work has me fired up, I have so many old left over computer parts I think Im going to make a custom case for it and just make a filer server out it. ^_^

    of course that will be after my FEAR project is done =p
     
  20. Guest-23315

    Guest-23315 Guest

    Loogs good :thumb:
     

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