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Cube case...completely from scratch.

H

homersapien

Limp Gawd
Joined
Jun 20, 2003
Messages
193
So, I need a new house for one of my HTPCs. Usually I mod them into an old receiver or what not, but this one is full sized ATX. Decided to go the cube route and try to make it look like half way decent. 14"x14". No ugly buttons, no tacky neon lights or distracting LCDs, just a straight up piece of furniture so to speak. Thus far everything is bent/shaped/welded from good old steel. There will be no tradional case parts. The only thing I won't fab are things like bolts/screws/etc.

I only have one pic so far, of the freshly welded frame (gasless welding = a$$, but it's all I had.) I'll probably skin the front and sides in aluminum and maybe do a wood veneer for the top. The back will be in aluminum as well. I will not be using a traditional back plane. Instead, I'm going to fab internal supports for the pci cards and have all of the wires come out of one hole. Keep in mind this is a HTPC...no drives, no monitor.

cube.jpg
 
Looks like a pretty good start to an interesting project...I'll definately be keeping an eye on this one. A question though...if you just want it to look like a piece of furniture, why not skin the whole thing in wood? you say no LCDs, are you not going to have anything for a status display? or will you be using a TV-out card? this is one thing I would love to do as well but the lack of funds prohibit.

can't wait for future updates
 
siege said:
Looks like a pretty good start to an interesting project...I'll definately be keeping an eye on this one. A question though...if you just want it to look like a piece of furniture, why not skin the whole thing in wood? you say no LCDs, are you not going to have anything for a status display? or will you be using a TV-out card? this is one thing I would love to do as well but the lack of funds prohibit.

can't wait for future updates
Click to expand...

I'll get some more pics later today maybe. I've begun slicing up sheet metal for the interior and mobo tray. I don't need an LCD as the comp runs totally headless. I control it via another machine. I'm still thinking about doing all wood veneer...ever try to bend <18 gauge aluminum or steel by hand? Yeah, not fun.
 
After some more welding. Some lexan for the back panel and mobo tray.

cube1.jpg


After some paint...bed liner coating. The aluminum will be the front/sides...maybe. I might use a stainless piece instead.

cube2.jpg
 
i was looking to make a custom enclosure. are you using aluminum or steel? how would you bend the metal?
 
I would guess Al and he probably used a break to bend the metal...nice job so far and can't wait to see more done on it
 
topdragon147 said:
i was looking to make a custom enclosure. are you using aluminum or steel? how would you bend the metal?
Click to expand...

Hi Topdragon. Aluminum vs. steel is sort of up in the air right now. I'm going to bend pieces of both and see which one I like. Aluminum is MUCH easier to work with obviously...easier to cut, easier to bend low gauge sheets. Just wish it were cheaper :D

I use a sheet metal bender/brake to to do the bending. You can get a cheap one for ~$20 at Harbor Freight tools: 18" bending brake. For smaller bends I use my 5" vise. However, you can accomplish the same thing if you have a sturdy bench. Just lay the metal on the bench, clamp a piece of steel square tubing on top of where you want the bend, and bend it with your hands. Another trick is to clamp it between two 2x4s and bend it against the ground. There is a mechanical advatange to the brake though, and it also makes cleaner bends.

For cutting I use a good old jigsaw with a 24t blade. VERY important to use a blade with as much teeth as possible. After that I clean up the cut with a grinder and then a belt sander.

Any other questions...feel free to ask. I'm hoping to finish things up this week.
 
Stainless mobo tray. Stainless exterior mounted to top panel. The mobo tray looks gorgeous, can't wait to peel the plastic off the exterior piece.

cube3.jpg

cube4.jpg
 
Almost there. Guess what stainless steel does to cheap drills and taps? Gonna have to wait on setting up the mobo tray. Fortunately McMaster is in the same state so my stuff gets here next day :D

Keeping it simple with the back. No need for any eye straining dremeling, just a few simple openings for wires to pass thru.

cube5.jpg


Couldn't resist. Had to peel the plastic off.
cube6.jpg
 
very very very nice job so far cant wait to see the finished product. what kinda welder did you use to weld the corner angle iron for your chassie?
 
homersapien said:
Almost there. Guess what stainless steel does to cheap drills and taps? Gonna have to wait on setting up the mobo tray. Fortunately McMaster is in the same state so my stuff gets here next day :D
Click to expand...

Mcmaster is the best site ever :)
 
Zombie said:
Mcmaster is the best site ever :)
Click to expand...

They are awesome. Every single order I've done has shipped the same day I place it.

ZeRo_Dark said:
what kinda welder did you use to weld the corner angle iron for your chassie?
Click to expand...

A buddy's mig welder. Flux wire welded it though (ugly stuff), since we were too cheap to fill his tank :D Then used JB Weld to smooth out the corners.

I'm in the home stretch. I'm waiting on some veneer, need to finish the drive cage, find some feet, and line the interior with foam.

cube8.jpg

cube9.jpg

cube10.jpg
 
MikeP said:
Is it wrong to dry hump my monitor when I see this pic?
Click to expand...

do you like metal? I am confused why you would want to hump that :confused: .

I mean dont get me wrong case is looking great, but that pic is of nowhere near the completed proj(at least i think). Wait until he is done to start humping his leg.


JEEVES
 
Your cube is flawless brotha. What do you weld with? And where did you get your welding equipment.
 
I just asked if it was wrong, not like Im actually, you know, doing anything, or not.

Its just looking damn sexy..thats all.
 
Finished the top piece. Sapeli ribbon with some dark stain I had laying around. The grain is fantastic, but my camera doesn't do macro shots worth a shit.

ribbon.jpg
 
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