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Rakesh Sharma

[Scratch Build] Phase Changer RIG. INDIA

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Hi,

 

I am Rakesh Sharma a software developer by profession but DIY type guy by heart, from a small town ‘Jodhpur’, INDIA.

 

DIY stuff is my hobby or better a passion ..

 

I have done few case builds, modding and making of water cooling kit from scratch..in past and posted in many forums. Few links are below..

 

http://www.erodov.com/forums/do-yourself-printed-circuit-board-making/33865.html

 

http://www.erodov.com/forums/new-case-build-name-clearity/29255.html

 

http://www.erodov.com/forums/field-biometrics-project/42741.html

 

http://www.erodov.com/forums/diy-watercooling-tec/43859.html

 

Now I am working on a new build, this time scratch building a Case from aluminum with Phase changer cooling.

 

For last few weeks was doing some R&D.. so now it’s time to start the build.

 

 

My inspiration for this build is this LD V10 case..

 

I will try my best to make my case as a clone of this case.. only the laser cut fan grills will be very-very difficult to be fabricated by hand..let’s see..

 

Just to add that I will not be using any type of power tools for this build..(Cos I don’t have any). All the cutting, drilling, grinding and finishing will be done by hands only.

 

Proud to announce Sponsor for this build :

1.

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ASUS sponsoring the project with Sabertooth P67 Motherboard

 

2.

Special Thanks to 'BIKeINSTEIN' and 'toolius'

 

3.

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ANTEC sponsoring the project with Case fans.

 

4.

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KINGSTON is supporting the project with some good Hardware.

 

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Here is rough layout of the build (just for idea..).

 

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Ok to Start, some half inch square aluminum rods purchased, at a super discount rate from a friend’s shop.

 

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All rods are of good quality ..My friend personally monitored that on piece should not have any type of manufacturing defect.

 

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Cutting the rods in proper size…

 

Dam they are too hard .. it took about 15 minutes to cut one end of four rods together.

 

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Filling all ends for proper 90 degree flat face..

 

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So after about three hours of late night work.. I have finished all the rods to be made in as a frame…

 

Next have to drill some holes, make threads for screw and join the frame together.

 

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Have finished cutting and finalizing the ends of the rods for the case frame.

Now have to drill holes and join the frame together.

 

First marking center of the rod.

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Punching hole for drilling.

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Hand drill in action.

Used new wooden drill bit set.. so drilling was very easy .. First I tried drill bits used for iron,, but they have very small cutting angle , so using with aluminum was very difficult . But wooden drill bit cuts aluminum very easy ..

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Primary holes done

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using three incremental sized drill bits , main hole for screw threading done.

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Threading.. Aluminum is very easy to work with.. effortless

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Screw baby screw.. perfect .

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More drilling threading.. whole night

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4 in the morning finished drilling and threading .. filling and tap holes for screws remains.. just tested how two rods joins.

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Time to join the monster together..

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Perfect tapping of screws.

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First top frame. Perfect right angle joints..

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Now bottom one.

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Both ready..

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More to go.. now top frame rod screwed.

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Front side ready…

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there goes back side too ..

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Frame is ready .. it look huge.. everyone in the house was saying.. this is too big for a PC..

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Just to give an idea how huge this frame is, I have placed a PSU .. so you can understand seriousness of the matter.

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Final the frame in done it’s about 4pm on Sunday..

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This build can take some time.. since I am fulltime Office employ and family executive at home. So full modding on weekends and tit-bits on weekdays.. you all can understand..

 

Update Pics ...

 

 

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First Compressor

 

 

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It’s 1/8 Hp compressor which can handle R404A gas,

Permitted Evaporating Temperature -47 .0 to -6.7 c (just specifations, can go more low with this compressor.)

Suction Pressure 24.6 psig

Discharge Pressure 354 psig

 

 

Some tools ..

 

 

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Second a Parcel ..

 

 

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I think i know what's it .....

 

 

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It’s a Sabertooth P67.. woooo.

 

 

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Sabertooth is having real looks.. super cool with that Thermal Armor.

 

 

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Cutting hole in mobo tray using Chisel and hammer.

 

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It took about 2 hours to cut hole for Mobo power cables and Real time temperature displays.

 

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Filling holes another hour gone..

 

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Cutting and mounting black acrylic sheet for temperature displays.

 

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Perfect.. Done

 

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Sunday Morning..

Color the tray and hdd stand.

First coat.

 

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About evening.. it's done..

 

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Looks cool..

 

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Got a package from Taiwan

 

 

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Some purchase:

 

 

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Just purchased a DVD Drive and colored it

 

 

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A card reader and few internal front panel cables..

 

 

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These cables are too short for my case.. So made some custom long cables

First Front panel cable

 

 

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Extra long com port connector

 

 

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Extra long front USB header cable, made from old Logitech wireless key-mouse receiver..

works perfect:

 

 

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Some real time temperature displays on place.

 

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Some holes for Fans.

 

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Front USB panel and hole for card reader.

 

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A controller or junction board to power fans, LEDs, power relays, etc is ready.

 

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Thanks to Rex Liang from KINGSTON, for supporting my PC build.

 

 

 

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unday update:

 

Worked late night and finished all major holes creating work on the case and PSU holder plate also done.

Now in morning testing all fittings.

 

First some good Black M4 5/6 Screws for fan and Phase changer Controller installed ..

 

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The Phase changer controller can be programmed for ten preset settings.

I have set three settings.

One for max oc.. maintain lowest possible temperature.

Second -2 degree for normal OC

And finally 6 degree for normal working.

It will control the compressor and the condenser fan according to preset setting.

 

 

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Now here comes my bad luck in action.

Controller is working fine . I have programmed it to start my test PSU at 40 degree C , which in turn start all four 140 fans.. cool..

But everything not went like this .

First mistake I selected same single color wires for all AC test wiring. (One must take different color wire for AC , line neural and earth ) then somehow I connected the main AC wires to the controller in such a way that it created a shot circuit better say a big blast and a black out in the house , as soon as I increased the temperature on the sense to 40 degree.

I have killed my brand new controller… Don’t have words to shout on myself

Even after two hours, one can sense a PCB burning type smell in whole house.

 

 

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Very bad Sunday .. Anyhow tried some cable sleeve one few old Fans.. first time sleeve so please don’t mind it.

 

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Rakesh Sharma

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