Project: External Radiator Case

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
I've been commissioned to build an external radiator case which is destined to sit on the top of an 800D. The case will be made entirely from aluminum and built to house two triple radiators.

Here's a drawing of the case:

800DRadBox2K.jpg


The frame of the case is made from 1-inch channel, 1/2 x 3/4-inch and 3/8 x 3/4 flat bar.

Parts.jpg



The corner blocks were made from 3/8 x 3/4 flat bar:

CornerBlocks.jpg



The alignment of all three corner pieces turned out to be spot-on:

MachiningAlignmentCU.jpg



The frame is fastened together with self tapping stainless screws.

FrameSubAssembly.jpg



Frame1.jpg


Frame2.jpg
 
Last edited:

SuperTroye

Limp Gawd
Joined
Apr 20, 2009
Messages
177
I absolutely love your work Spotswood... subbed for sure! Looking forward to seeing this come together. Thanks for all your high quality posts!
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
@xDezor - Thanks.

@SuperTroye - Thanks. I'm eager to see how this turns out as well. hehe
 

Axdrenalin

[H]ard|DCer of the Month - Nov. 2009
Joined
Jan 28, 2004
Messages
6,220
Tossing in a sub here as well. Enjoy seeing the creative ideas that Spotswood comes up with.
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
I cut out the bottom, top and sides of the case with my hand held router, guided by a straight edge.

PanelsCut.jpg


The entire bottom of the case is perforated aluminum so as not to impede the exhaust from the 800D, eventually standing on some nice beefy mnpctech case feet.

BottomMeshAttached.jpg


BottomMeshNutsDetail.jpg


BottomMeshBoltDetailCU.jpg
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
Side panels bolted on with stainless steel socket cap flat head bolts.

SidePanelsBoltedOn3.jpg


SidePanelsBoltedOn2.jpg



Up on mnpctech case feet:

SidePanelsBoltedOn1.jpg


FHBoltCU.jpg
 

CMadki4

Supreme [H]ardness
Joined
Feb 3, 2011
Messages
4,438
Thanks. I use Google's Sketchup.

Huh, I didn't know Google Sketchup had such a nice look to it. I'm a SolidWorks junky. But I might have to give Google Sketchup a try for renderings that don't require CAM.
 

jebo_4jc

[H]ard|DCer of the Month - April 2011
Joined
Apr 8, 2005
Messages
14,552
how will the rads be set up? blowing in opposite directions with the small ends of the box being the intakes?
 

Drudenhaus

2[H]4U
Joined
Sep 27, 2005
Messages
3,119
Fantastic. I've thought of attempting something like this myself and then switching my main case to something much smaller and attaching the WC case via QDs.
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
how will the rads be set up? blowing in opposite directions with the small ends of the box being the intakes?

I think this will be a push setup, out of the case. The intake will come from underneath.

Fantastic. I've thought of attempting something like this myself and then switching my main case to something much smaller and attaching the WC case via QDs.

Yes, this case will have holes drilled for quick connect/dis-connects.
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
Cut out the openings in the sides for the rad exhaust.

RadCutOut.jpg


RadCutOutEdgeCU.jpg



The back of the case has a removable sub-panel to make it easier to reconfigure things in the future:
BackPlate.jpg



I drilled two 18mm holes for Koolance's quick-disconnect panel fittings.

BackPlateCU.jpg
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
Small update...

Taped the top support beams for #6 bolts and attached the top sheet with six stainless steel flat head socket cap screws.

TopAttached.jpg




Cut the perforated aluminum which will be affixed to the side panels using Hi-Temp Lab-metal.

SidePerfAlCut.jpg



Cut a slot in the back "inset/sub-panel" for the power cord.

PowerCordSlotCut.jpg
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
Cut the front sheet, routed out the hole for the 5.25-inch bays and squared the inside corners with my trusty file.

FrontSheet.jpg


FrontSheetCU.jpg
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
Completed the cage for the 5.25-inch bay devices.

A full size printout from a Sketchup model was taped to the .10-inch aluminum sheet.

DriveRails1.jpg



A 3/16-inch router bit and plunge router were used to router out the mounting slots.

DriveRailsRouter.jpg


DriveRails4.jpg



Two small pieces of 1/2-inch angle and the "cage" was done.

DriveRails3.jpg


DriveRails5.jpg


DriveRails6.jpg
 

Arcygenical

Fully [H]
Joined
Jun 10, 2005
Messages
25,059
Wait, you can print to scale from sketchup?
Why the fuck did I never try that before. Shit.

You're my hero - and your metalworking skills are top-notch. Those are some straight ass cuts. GJ
 

Spotswood

Gawd
Joined
Sep 5, 2009
Messages
709
I added the radiator supports, made from .25 x 1-inch and .125 x 2.5-inch aluminum flat bar. I hope they are strong enough. ;)


RadSupports2.jpg



RadSupports3.jpg



RadSupports1.jpg
 

wra18th

Supreme [H]ardness
Joined
Nov 11, 2009
Messages
7,960
I'm impressed all over again every time I look at this build. Well done!
 
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