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It's Modding Time Again


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#1 Fueler

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Posted 27 February 2007 - 11:08 AM

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In an effort to get my electric bill under control I shut down 8 of my folding rigs (I donated these to a local charity...I can use the tax write off) and have replaced them with 2 E6300 rigs running the new SMP client.

Now I need a case for them....here's the plan:
  • Put both PC's in one case
  • Run both PC's from one power supply
  • No optical drives
  • Integrated video
  • Minimum number of fans
I have also set some parimeters for the case.
  • It has to blend in with the rest of the furnishings in my office
  • I'm shooting for a retro look (sorta like the stereo receivers from the 70's and 80's with the wooden end caps)
  • Keep the case as compact as possible (I'm using mini atx motherboards but two of them still take up alot of space)
  • I don't want anything on the front bezel (no switches, ports, nothing....)
  • Unlike my previous cases this one will be made from aluminum not steel
  • For ease of maintenance the front bezel and side panels will be held in place by magnets (no tools required)
Ok that's enough to get started the rest I will just have to figure out as I go along.

I will be using 3/4" square aluminum tubing to make the frame so I needed to find a way to bolt or rivet them together, nothing I found at the local hardware store would do the trick so I decided to make the "L brackets" I needed from scratch.

I picked up a section of 1 1/2" angled aluminum rod and cut it into a load of 3/4" wide "L" shaped brackets

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That was just the start though, to finish them up took quite a bit more work....First they all (30 pieces) needed to be milled to exactly the same size.

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Each bracket will have 4 rivets going through it so the next step after sizing was to counter sink the brackets for the rivet heads. Four counter sinks per bracket times thirty brackets.....It took awhile. I used a dial indicator that reads in .001inch increments so that I could make sure that every bracket was done identically.

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I used the same proceedure to drill the holes for the rivets to go through.

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Finally after a run through the bead blaster and the better part of a days time I had the brackets for the case.

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Now it was time to cut the tubing for the case so some decisions needed to be made. I sat there and laid out those mobo's for a couple of hours trying to get the best fit and still have good airflow when I came across the idea of mounting the boards back to back. In order to make this work the case would have to be wider than a standard case (about 10") but the other dimensions could be kept to about the size of a mini or mid tower. I fired up the bandsaw, cut the tubing (I cut them a little oversized) and cleaned up (read squared) the ends using a bench mounted belt sander.

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The tubing then went to the mill and using the same proceedures I used for the brackets predrilled all the holes for the rivets.

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This is where all the time spend milling and drilling to exact tolerances paid off.....It took me all of about a half an hour to assemble the case frame and everything fit like a glove.

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More to come B:)

#2 sdy284

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Posted 27 February 2007 - 11:15 AM

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everyone likes a build by Fueler!

#3 Verran

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Posted 27 February 2007 - 11:25 AM

You know, we all know that Fueler builds some amazing stuff.... but he also puts together a mighty fine worklog as well.

I love following these! Good luck man, and I can't wait to see more. :)
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#4 Nemo

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Posted 27 February 2007 - 11:46 AM

It's like reading a novel published bit by bit in a magazine - can't wait for the next installment! This will certainly look a LOT more professional than the two folding rigs I have running off one power supply - they're just sitting jumbled up on a set of Wal-Mart plastic shelves :P - I call it my WallyWorld rack mount.

Intel Core 2 Quad Q9550 2.83GHz / ASUS P5Q Deluxe / Patriot Extreme Performance 2GB PC2-9600 DDR2-1200MHz / 2x Seagate ST3160827AS 160GB RAID 1 / Seagate ST31000340AS 1TB
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"however, i cannot claim to be such a fish as i am not a fish at all..." - hardnrg,Jul 4 2005, 02:49 PM
 

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#5 kingdingeling

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Posted 27 February 2007 - 12:14 PM

awesome fueler, I'm already deperate for more! Putting 2 rigs in one case is always a hard thing to do. I tried, and failed miserably (was a wooden case, I didn't think the PSU would be as heavy.... when I mounted everything and moved it into my room, put the case down, the psu falls out of place and breaks the mainboard and GPU... was old stuff, but still...)

I guess I have no excuse for not being as awesome as King... - iKillSteal

Seriously, big credit goes out to King for maintaining this list. He puts a lot of work into this thing and he deserves our thanks! - Verran

RIP

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#6 sdy284

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Posted 27 February 2007 - 12:14 PM

i'm sure somebody has asked you this before Fueler, but what do you use to design your before you start cutting?

#7 Fueler

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Posted 27 February 2007 - 12:27 PM

i'm sure somebody has asked you this before Fueler, but what do you use to design your before you start cutting?


As much as I'd like to say I use one of those fancy 3D design tools (like Sketchup) the reality is I don't have a clue how to use those programs so it's all in my head (probably explains the headaches). :lol:

#8 sdy284

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Posted 27 February 2007 - 12:45 PM

As much as I'd like to say I use one of those fancy 3D design tools (like Sketchup) the reality is I don't have a clue how to use those programs so it's all in my head (probably explains the headaches). :lol:


wow, thats even more impressive then

do you draw a basic layout design on paper first before you do anything?

#9 Fueler

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Posted 27 February 2007 - 12:58 PM

wow, thats even more impressive then

do you draw a basic layout design on paper first before you do anything?


Yeah, sure....here's the work sheet for this rig

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It ain't much but it's all I need B:)

#10 sdy284

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Posted 27 February 2007 - 01:10 PM

wow, props to you man :)

but i guess when you've been at modding for as long as you have, you start to get the hang of what you need & what needs to be done to get there ;)

#11 Guest_Fried_fry_*

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Posted 27 February 2007 - 01:17 PM

Here we go again... :P

Already starting to look good, cant wait for more to come!

#12 Andrewr05

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Posted 27 February 2007 - 01:20 PM

It ain't much but it's all I need B:)

Some people (like my father) cant do anything without making a list, diagram, or sketch and some people (like you and I) can just go off of a whim or a mental picture.

I always enjoy your builds fueler, everything you build has a purpose and you build everything so precise so it fits the first time...
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