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This log was started over on the DIY-Street forums last summer; now that the merger has taken place it's coming over here ;)

I've been working on a Custom acrylic PC case that I designed.

Case features a double sidewall to allow intake air without the need of front holes; also good for cable routing. Designed to hold 2 360mm Radiators; will only use one ATM with a Y-line loop. Stealthed CD slot; will wire the eject button and activity LED to an illuminated pushbutton to preserve the clean look of the front panel.

Here are some pics of the 3D model in it's current state. I'll update with pics of the actual build as well.

[img]http://ocidb.com/albums/userpics/10005/PC1.jpg[/img]

[img]http://ocidb.com/albums/userpics/10005/PC2.jpg[/img]

[img]http://ocidb.com/albums/userpics/10005/PC3.jpg[/img]

[img]http://ocidb.com/albums/userpics/10005/PC4.jpg[/img]

[img]http://ocidb.com/albums/userpics/10005/PC5.jpg[/img]

Expected Hardware Requirements:
DFI Lanparty UT 680i SLI T2R/G ---- Out of pocket
Intel Q6600 G0 ---- Out of pocket
Creative X-Fi XtremeGamer ---- Out of pocket
2x BFG 8800GTX ---- Out of pocket
2x1Gb DDR2 RAM (been eying the Corsair Dominator PC2-10000)
Lite-On SATA DVD burner ---- Out of pocket
Silverstone ST1000 Modular PSU ---- Out of pocket
500+Gb SATA2 HDD ---- Out of pocket
2x X-Flow Black Ice Extreme III ---- Sponsored by DangerDen
Variable speed D5 ---- Sponsored by DangerDen
20 feet 1/2" ID Tygon ---- Sponsored by DangerDen
2x Brass Fill-port ---- Sponsored by DangerDen
TDX for LGA775 ---- Sponsored by DangerDen
Maze4 chipset block (regular block) ---- Sponsored by DangerDen
875 chipset block ---- Sponsored by DangerDen
2x 8800 GTX blocks ---- Sponsored by DangerDen
2x single-slot PCI bracket for the 8800s ---- Sponsored by DangerDen
Fill-port Reservoir ---- Sponsored by DangerDen
6x 120mm Case Fans ---- Sponsored by A.C.Ryan
Wire-sleeving ---- Sponsored by A.C.Ryan
2x dual 30cm red CCFLs ---- Sponsored by A.C.Ryan
dual 30cm UV CCFLs ---- Sponsored by A.C.Ryan
dual 20cm UV CCFLs ---- Sponsored by A.C.Ryan
Acrylic Case feet ---- Sponsored by Petra's Tech Shop
H2O Dies ---- Sponsored by Petra's Tech Shop
Biocide H2O additive ---- Sponsored by Petra's Tech Shop
AS5 ---- Sponsored by Petra's Tech Shop
36" SATA2 cables ---- Sponsored by Petra's Tech Shop


[b]Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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[b][size=4]Start of Worklog (28-July-2007): MB panel[/size][/b]

I spent last night and today working on the motherboard panel.

[b]Sketched panel in Pro/E[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel.JPG[/img]

[b]Masked the Acrylic sheet and marked the locations for the MB standoffs, RAD, and Front-panel port mounts.[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel1.jpg[/img]

[b]With old MB to verify markings[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel2.jpg[/img]

[b]Drilled pilot holes[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel3.jpg[/img]

[b]Cutting the fan/RAD holes[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel4.jpg[/img]

[b]Finished fan/Rad holes[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel5.jpg[/img]

[b]Drilled out holes to secure the RAD[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel6.jpg[/img]

[b]Illustration of MB standoff mounting[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel7.jpg[/img]

[b]Drilled out and threaded holes for MB standoffs and FPIO mount[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel8.jpg[/img]

[b]Unmasked panel[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel9.jpg[/img]
[b]
Mounting of FPIO[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel10.jpg[/img]

[b]Added slots for cable pass-through. All cabling will be routed underneath the MB panel[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel11.jpg[/img]
[b]
Test fit of my current MB and FPIO ports[/b]
[img]http://ocidb.com/albums/userpics/10005/MB-Panel12.jpg[/img]

[img]http://ocidb.com/albums/userpics/10005/MB-Panel13.jpg[/img]

I don't have the new RAD/fans yet so I couldn't test fit those.

If anyone would like to see other detail shots/angles please LMK

[b]Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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[b][size=4]Update (29-July-2007): Drive bays[/size][/b]

[b]Today I started working on the drive Bays:
[img]http://ocidb.com/albums/userpics/10005/3-5_Drive_Bay.JPG[/img]

[img]http://ocidb.com/albums/userpics/10005/5-25_Drive_Bay.JPG[/img]

Laid out the parts on the masked acrylic:
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays1.jpg[/img]

The cut out panels:
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays2.jpg[/img]

Threaded side panels for drive retention mechanism (will into detail on that later):
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays3.jpg[/img]

Cut drive support rails:
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays4.jpg[/img]

Unmasked 5 1/4 bay panels:
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays5.jpg[/img]

Unmasked 3 1/2 bay panels:
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays6.jpg[/img]

I have to wait on an order from US Plastics before I can glue these parts together.

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b] Edited by radodrill

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[b][size=4]Update (01-Aug-2007): Corner Blocks & 3.5" bays[/size][/b]

[b]Today I received the 1" Acrylic cubes that I'll use to assemble the main panels of the case
[img]http://ocidb.com/albums/userpics/10005/Corner_Block1.jpg[/img]

Drilled/Tapped the cubes so that I could screw on the panels
[img]http://ocidb.com/albums/userpics/10005/Corner_Block2.jpg[/img]

Closeup of one cube
[img]http://ocidb.com/albums/userpics/10005/Corner_Block3.jpg[/img]

Next I polished the parts for the 3.5" drive bay
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays7.jpg[/img]

3.5" Drive bays clamped and glued
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays8.jpg[/img]

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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[b][size=4]Update (02-Aug-2007): Drive bays[/size][/b]

[b]Finished the 3 1/2" drive bays
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays9.jpg[/img]

Drive retention mechanism; screws on one side with nylon spacers on the ends
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays10.jpg[/img]

Test fit with old drive
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays11.jpg[/img]

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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[b][size=4]Update (05-Aug-2007): Drive Bays, Outer panels[/size][/b]

[b]Polished 5 1/4" drive bay panels
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays12.jpg[/img]

5 1/4" bay panels glued together
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays13.jpg[/img]

Finished 5 1/4" Drive Bays
[img]http://ocidb.com/albums/userpics/10005/Drive-Bays14.jpg[/img]

I also polished the MB panel
[img]http://ocidb.com/albums/userpics/10005/MB-Panel14.jpg[/img]

Laid out side, front, and back panels
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels1.jpg[/img]

Cut out front/back panels
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels2.jpg[/img]

Cut out side panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels3.jpg[/img]

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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[b][size=4]Update (08-Aug-07): Outer Panels[/size][/b]

Just a small update; should have more by the weekend
Looks like A.C. Ryan may be providing some sponsorship as well.
[b]Laid out top, bottom, and other side panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels4.jpg[/img]

Cut out top and bottom panels
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels5.jpg[/img]

Cut out side panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels6.jpg[/img]

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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[b][size=4]Update (11-Aug-07): Outer Panels[/size][/b]

[b]Drilled screwholes into the first side panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels7.jpg[/img]

Same for the other side panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels8.jpg[/img]

Screwholes and fill-port hole in the top panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels9.jpg[/img]

Introducing the Dremel's big brother :D
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels10.jpg[/img]

Screwholes, drainport, and air intake slots in the bottom panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels11.jpg[/img]

Test-fit assembled outer panels; had to sand some of the corner blocks and panels to achieve a perfect fit
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels12.jpg[/img]

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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[b][size=4]Update (14-Aug-07): Back Panel[/size][/b]

[b]Yesterday I received the pushbutton switches for this case; some ring-illuminated momentary switches, dot-illuminated latching switches, and a non-illuminated momentary switch
[img]http://ocidb.com/albums/userpics/10005/Pushbuttons.jpg[/img]

I added some stops to the panels to ensure flush edges
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels13.jpg[/img]

Laid out the back panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels14.jpg[/img]

Cut out back panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels15.jpg[/img]

Fitted into the back of the case
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels16.jpg[/img]

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b] Edited by radodrill

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[b][size=4]A.C.Ryan Supplies[/size][/b]

[b]This Morning I received a package from A.C. Ryan containing fans, CCFLs, and wire sleeving supplies
[img]http://i116.photobucket.com/albums/o34/radodrill/Case-Project/ACRyan1.jpg[/img]

Time for some eye-candy :D
Kameleon Fan; translucent black under normal light
[img]http://ocidb.com/albums/userpics/10005/ACRyan2.jpg[/img]

And Blue under UV
[img]http://ocidb.com/albums/userpics/10005/ACRyan3.jpg[/img]

With the fan on:
[img]http://ocidb.com/albums/userpics/10005/ACRyan4.jpg[/img]

Red Twin Overburst CCFLs
[img]http://ocidb.com/albums/userpics/10005/ACRyan5.jpg[/img]

UV Twin Overburst CCFLs
[img]http://ocidb.com/albums/userpics/10005/ACRyan6.jpg[/img]

And the money shot :D
Fan and wire sleeving in full UV splendor:
[img]http://ocidb.com/albums/userpics/10005/ACRyan7.jpg[/img]

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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[b][size=4]Update (18-Aug-07): Outer Panels[/size][/b]

[b]Long awaited update :D

Laid out Front Panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels17.jpg[/img]

Cut out Front Panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels18.jpg[/img]

Assembled Outer Panels

[img]http://ocidb.com/albums/userpics/10005/Outer-Panels19.jpg[/img]

[size=5]Rounded the edges; note, only the outside edges have rounds[/size]
Top and Bottom Panels
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels20.jpg[/img]

Front and Back Panels
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels21.jpg[/img]

Left Panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels22.jpg[/img]

Right Panel
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels23.jpg[/img]

Tomorrow I'll put it back together and sand all the edges and blend the corners. I hope to get it polished tomorrow as well; But I may work on a wheeled base for it

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b] Edited by radodrill

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[b][size=4]Update (19-Aug-07): Outer Panels[/size][/b]

[b]Just a small update today; but it give a good perspective of what the finished product will look like

Sanded the edges to blend the corners together
[img]http://ocidb.com/albums/userpics/10005/Outer-Panels24.jpg[/img]

Assembled the panels with switches and FPIO to give an idea of how the case will look
[img]http://ocidb.com/albums/userpics/10005/Case1.jpg[/img]

I still have to polish up the edges and install the drive bays; then the case itself will be basically complete.

Sponsors:
[url="http://dangerden.com/"][img]http://ocidb.com/albums/userpics/10005/DangerDen.jpg[/img][/url] [url="http://acryan.com"][img]http://ocidb.com/albums/userpics/10005/A_C_Ryan.jpg[/img][/url] [url="http://petrastechshop.com/"][img]http://ocidb.com/albums/userpics/10005/PTS.jpg[/img][/url][/b]

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