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input on a server case fabrication

I

IDversusEGO

Supreme [H]ardness
Joined
Oct 30, 2003
Messages
5,015
Now before I get to far into this, I know I could have one mega server to do the functions I need, but it would require starting from scratch, and I don't have the money for it now. One day, just not yet.

I have the need for 2 servers with a large number of hard drives in them. I haven't been able to find anything with the space, cooling, and price features I need. So I am going to build one case to house both servers. I thought about 2 CM stackers, but I don't have the $$ for it. I Need room for about 15-16 hard drives and 2-5 opticals. The 2 server is a combo of a file server and a sageTV television server. I need the 2 servers to handle the 8 PCI cards I have (5 tuners and 3 raid controllers). And of course I want to attempt to make it as cool and quiet as possible. I am thinking steel or wood (because it is easy to work with and could be made as a pice of furniture in my office). I want a seperate area for hard drives with 120mm fans cooling them at low voltage. I am not sure about PSU placement. I basically can think of 3 options.

1. bottom mounted with intake fan pulling cool air and the exhaust going out of the back.
2. top mounted in HDD area pulling air from hard drive area
3. witht he motherboards.

3 seems like worst idea becuase of the hot air from the CPUs. 1 seems best with proper filters. I plan on using undervolted yate loon fans, zalman CPU coolers, and internal sound dampening. All northbridge fans and video cards are passive. So any options or items I should consider?
 
2 mobos?? well i would build it out of aluminum, on the inside and the frame at least, and then if you want to make it look like a furnature piece use MDF on the outside. Aluminum is easier to work with than steel. www.metalexpress.net should have all the aluminum you would need for the project. some tools like a holesaw would be essential for cutting a hole for the fan.
 
kahm said:
Check out Tcalp's Big Mother Server from the worklogs:

http://www.hardforum.com/showthread.php?t=1014451
Click to expand...
thanks for the link, I'll read tonight.

Darkala said:
2 mobos?? well i would build it out of aluminum, on the inside and the frame at least, and then if you want to make it look like a furnature piece use MDF on the outside. Aluminum is easier to work with than steel. www.metalexpress.net should have all the aluminum you would need for the project. some tools like a holesaw would be essential for cutting a hole for the fan.
Click to expand...

Yeah, I have most of the tools I'll need. table saw, hole saws, jigsaw with wood and metal blades, dremels, drill press. I wish I had a riveter, but not yet. I plan on making the skeleton out of metal. might even be able to break down some existing older cases for parts. like the drive cages. Like I said I need the 2 mobos to support all the PCI cards. One day I'll get a dual CPU mobo with tons of SATA raid controllers on board. then I'll get dual tuner cards instead of singles. but that would cost at least $1g. toss in the beefy PSU for all those drives and it's a good bit more.
 
Hey ID,

Here's a little idea. Build it out of 3/4" plywood, the nice veneer covered stuff. This way you could laquer it, or poly it and make it look like a piece of furniture. Plus it's sturdy enough so you wont need to make a metal frame too.

You build a box, and put a divider up the middle. The front, top, bottom, and back are fixed, and you put a door on the left and right.

On one side you have both motherboards, one on top and one on the bottom attached to the middle divider.

Then you have the other side for all your drives. You could place some up front and some in back depending on the drive type and length of cable.

You'd also have plenty of room for PSU's wherever works well.

Juts thoughts, I havent had quite enough coffee yet this monring though. :D
 
good thoughts. I have pretty much decided on a wood case. I think I am going to build one large cabinet for my 2 servers, a mouse, keyboard, monitor, the 4 directv boxes, and my networking equipment. I will still use metal for drive cages though. both Mobos on same side would make it pretty tall. I was thinking one on each side. It would force on to be inverted, but that isn't a big deal I don't think. so I was thinking same as you. One space with a middle divider. Drives on one side, PSU's and Mobos on other. The front would be built like a cabinet. Nice trimmed up cabinet doors that I pull open for acces to the cards and stuff.

For the mobos, they go on removable mobo trays that I could slide out from the back. PSU's on bottom pulling air from underneath. should keep the thermally controlled PSU's from spinning up very loud from ambient case temps. I was thinking of integrating a KVM switch, gigabit network switch, and power strip as well. I would love to integrate as much of the clutter as I can.
 
Sounds like a neat idea. You can get rack rails really cheap from www.musiciansfriend.com if you wanted to use rack mount gear.

Maybe you could pick up a tall kitchen cabinet from a Home Depot or something and mod your gear into it? Might save some work.

I built a rack into an leftover kitchen cabinet that was in the basement of my house when I moved in. All I had to do was move the trim out a couple inches and it was the perfect rack width!
 
I actually started a new AV cabinet and changed my mind about 3/4 of the way through. Might just mod it for this project. as for the drive cages, I am either going to rip them from some existing cases or use PS-RagE's idea about shelving rails...
newservr16.jpg


I would also love to recable the PSUs with right angle molex connectors and custom lengths for a cleaner look, but will probably save that for later.
 
Or you could buy two CM Stackers and bolt them together :p

Four PSU's, assloads of hard drives.

hmm, I better stop before I cost myself money! :D
 
using Lian Li mobo trays makes building a custom case a hell of a lot easier
 
Darkala said:
using Lian Li mobo trays makes building a custom case a hell of a lot easier
Click to expand...
checked Lian Li site and didn't see them available for individual sale. Link me up please?
 
oohh mroe info :) im more interested in building myself a large hdd rack for 12 or so wut sthe spacing/type of them shelves?
 
the shelf brackets for the HDD I got is Home Depot item # 070042434323 and is 72" for $2.65. I'll be chopping it tonight and I'll start a worklog.
 
I have decided to go with a straight up mod first, then take my time with the custom fab. Click the thumbs for slightly larger pics.

here is the blank slate I am going to start with...


here is the first crack at the drive mountings...

 
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