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Project "Mars" - Scratch Aluminium mATX Case

W

Whispermod

n00b
Joined
Aug 26, 2010
Messages
8
About Me​

I am a self-confessed modding addict: I have built a number of computer cases from scratch so far, and I don't plan to stop any time soon. My portfolio so far includes an ATX acrylic cube, "Paroxysm"; and an untra-SFF mini-ITX HTPC, "Eyas". To keep my modding alive, I try to sell each mod for more than I spent on it and for the mostpart, I succeed. I also do a few modding things like sleeving PSUs to help raise funds for this money-sink!

Both these cases have won Overclock.net's Mod of the Month competition.





Oh, and my favourite food is steak and chips.​

Introduction - Project "Mars"
​

The plan here was to incorporate performance watercooling for the mATX form factor. With the Antec P180 as a benchmark, I set out to design a suitable case that would be watercooling ready. I didn't want to sacrifice size, so I took some inspiration from Eyas and some cheap mATX cases on the market.

I'm very happy with the design, and hopefully being a complete beginner to metalworking won't hold me back on this one. As I plan to make the whole case out of aluminium.

Updates​

24 August 2010 ~ Sketchup Design Complete
28 August 2010 ~ First Adventures into Aluminium Land
29 August 2010 ~ Motherboard Tray Painting
30 August 2010 ~ Main Panel Bending

Timelapse

*Please watch all timelapse in at least 480p, due to the high framerate (60)*

YouTube- Project "Mars" - Update 1 - Timelapse

YouTube- Project "Mars" - Update 2 - Timelapse

YouTube- Project "Mars" - Update 3 - Timelapse


002.jpg

Parts List​

Amazon.co.uk ~ Shipping £8.69
760mm Sheet Metal Folder - £60
1" Dia. Rubber Case Feet - £0.81
Black Adhesive Felt - £1.98
400ml Surface Primer Grey -£5.49
400ml Black Matt Paint - £5.49
400ml Matt Clear Coat - £6.49
55m 38mm Painter's Masking Tape - £6.99
J.B. Weld Metal Repair - £4.99​

Ebay ~ Shipping £0.00
M3 Nuts Pk. 50 - £1.35
3.2mm x 8 Black Rivets - £2.75
M4x35 Black Cap Screws Pk. 20 - £2.79
M3x8 Black Cap Screws Pk. 20 - £1.99​

Ebuyer ~ Shipping + VAT £7.25
Startech M3x1/4" Crosshead Screws Pk. 50 - £1.26
Super Slim Micro ATX Mini Tower Case w/ 200W PSU - £19.56
​
Hindleys ~ Shipping + VAT £14.59
2m Aluminium Square Rod 9.5mm - £3.90
2x 4'x2' 2mm Aluminium Sheet - £32.30
1.5m 0.5"x0.5" Aluminium Angle - £1.83
Centre Punch - £1.70​

I also have a bid on a dead mATX motherboard which I will use for evil modding purposes. Oh, and that mATX case from Ebuyer?... It won't last long!

Total: £196.70

Stay tuned...
 
Last edited:
24th August 2010 - Update 0, Sketchup Design and Render​

So here we have it, an m-ATX performance case. I think it has a sort of Mountain Mods/Lian Li look to it.

001.jpg


But there's one thing that makes this case stand out compared to the regular mATX builds you see on the market. As anyone who has picked up a pen and paper (or sketchup) will know, the beauty of case design is on the inside. And now you begin to see why some may prefer this design to the ol' classics like the P180.

002.jpg


This needs some explaining. Beginning with the standard stuff, we have two hard drive bays on the bottom, and a 5.25" at the top. A standard ATX power supply, which may slide out the back of the case. It will also supports up to mATX form factor with full length graphics cards.

And the unique point? Well, it can accomodate a thick 240 radiator on the front, and a 120 on the top. The pump, if you're wondering, is behind the 240 radiator. There's a nice little space for it!

It has a few limitations - for example, if you wanted to stick with air-cooling there isn't exactly a huge space for a heatsink. And cable management might be a little bit difficult.

And finally, here's a pretty little render for you - it's quite hard to capture a brushed aluminium texture unfortunately.
003.jpg


Stay tuned...
 
Let me be the first to say that this looks pretty cool, cant wait to see the finished product. BTW, I really like that second case you made, simple but elegant
 
Thanks B-Sal, it's my first time working with Aluminium so it will be a steep learning curve. But I think the end result will be worth it.

And thank you for the compliments on Eyas, the worklog is exclusive to OCN for competitive purposes - otherwise I would post it here too. When you have a look inside it you can really appreciate it, there is less than 3mm between all the components - from slimline optical, to hard drive, to motherboard, to cooling fan; and the new owner is very happy with it!

I should be starting the mod-work tomorrow!
 
Update 1 - First adventures into aluminiun land!

For those that havn't seen any of my worklogs before, I prefer to show as much about the path I took as I can. I believe worklogs should be about the journey as well as the final product. It's hard to gauge all the work that goes into some projects until you can see every problem encountered!

*Sorry for the poor photo quality, the camera is with the family in Italy right now, and will be returned on Tuesday*

I started work this afternoon, to find that I was missing a cutting bit for the jigsaw. After 2 trips into town on my bike I finally found the right part and got to work. I'm finding aluminium really nice to work with, so much nicer than acrylic! The jigsaw doesent need an edge guide setting up, so cutting is much quicker; and the router handles the edges very cleanly.

Today, I started on the motherboard tray - my main reasoning is that most of this piece is hidden, so if I make any beginners' mistakes they wont be so visible!

I marked out the dimensions of the panel on painter's tape. Set-squares and steel rules at the ready.
001.jpg


A freshly cut piece of aluminium, the edges are a little wavy after the jigsaw job (I'm not good at straight lines...) but this doesent matter, as I deliberately cut a couple of millimetres too large so that I can route it along a straight edge.
002.jpg


After a little white spirit solution, it looks much shinier. This is preparation for the brushing.
003.jpg


Here's my home-made brushing "arm", simply two pieces of wood clamped perpendicular to each other so that I get smooth brushing lines. I sandwiched a rag beneath the piece of wood so that even pressure is applied to the whole panel, to ensure a uniform look.
005.jpg


After a few tugs on the wooden contraption... That was almost too easy!
004.jpg


That was on the nice side of the metal which was covered in a protective film in the factory - the otherside is unfortunately very scratched, not my doing - it came like that. I have no way to remove them so I'll just try and make sure none of them are visible.
007.jpg


I taped up both sides to keep the grease out and stop any further scratching, then routed down each edge to make sure they werent wiggly! When brushing aluminium you are typically left with a thin strip down each side of the material which doesent get brushed properly. The simplest way around this is just to trim the material after brushing. Also the same reason that I brushed it before any extra cutting on the panel.

I started by cutting out the access hole for the CPU backplate. Process: drilled M7 in 4 places, insert jigsaw, cut to the corners, then route out a smooth finish. Here's a photo mid-route showing the edge guide set up for the next edge.
008.jpg


It doesent seem like much, but that took a long time, particularly with cycling across town twice! I am in the process of cutting out some cable management holes, which I should finish tomorrow. I also hope to remove the covering tape and apply a few layers of primer.

Stay tuned...
 
Go fast or go home.. gief cookie

Saw u on ST forums, nice lil project, I need to design my case soon. The only issue I'm having with my design is how to attach the side and top panels yet have them removeable? I was thinking about making side and top all one piece and it screwing into place at the bottom with a couple of nice cap screws? Idk what to lol
 
I've run out of cookies :p

Yeah that would work quite well, you shouldnt worry about having screws visible though. So long as they're black or something.
 
Update 2 - Motherboard Mounting, Folding Attempt, Paint.

Phew, long day. It seems to take a long time to get anything done with aluminium :eek: Fewer photos today because there's not much to show, the timelapse will show all the work going in!

I tried to fold the edge of the motherboard panel, about a 10mm strip down one side - but the folding contraption wasn't having any of it. It didnt have enough purchase on the thin strip to allow it to bend - instead it just slid and popped out of the grip. There must have been some tremendous force going on because those vices were screwed up tight!

Anyway, I finished 4 cable management holes in the motherboard, drilled and tapped the stand-off holes and mounted the motherboard. I'm so glad I have this dead motherboard, it makes things so simple!
001.jpg


2 coats of primer - I shouldnt have done this painting in the garage, that was stupid of me, since it got covered in dust between coats. I'll set up a paint-shack next time I do any painting. I also need to brush harder, it's hardly visible any more.
002.jpg


This is the main panel, it will bend round to create the bottom, front and top. I begin tomorrow by cutting all the necessary holes in it - Fans, DVD, Power Button, USB/headphone, ventilation...
003.jpg


Update 2 - TIMELAPSE

Please watch this in at least 480p if you can, it goes pretty weird on anything lower.
YouTube- Project "Mars" - Aluminium mATX ~ Update 2 *TIMELAPSE*


A bouncing ginger and some metal folding struggles feature heavily in this movie.
 
Update 3 - Clamp Madness, Main Panel Bent to Shape.

Another big day today, although I don't have much to show for it. The first 3 hours were spent marking up the main panel - this took forever; then I drilled a few holes for the fan mounting. Rather than cut out the fan holes and DVD drive slot I decided to fold the metal first - I didnt want to weaken the aluminium before the bending.

Here's the main panel just before I routed a straight edge down the side. I have a load of dead-straight mahogany strips in the garage, absolutely priceless scrap wood that feature in all my mods - I don't know what I would do for edge-guides without these!
Following the routing came the long and arduous task of marking up all the cuts, folds and drill-holes I would need to do this panel. What's that saying - measure, measure, measure.. measure?
(I'm growing fond of that painters tape, it has such a nice texture to it! I almost think I should just leave it on...)
001.jpg


Bending the corners: I was scared of this part, with fairly good reason. My recent exposure to bending aluminium had shown me that 2mm aluminium was a bit tougher than I had imagined. A heatgun soon put rest to this fear though.
I am bending the corners around a metal tube from an old vacuum cleaner (ghetto!) which had a 17.5mm radius, I couldnt use the metal brake for this.

Yes, there's 12 clamps.... I even had to use a bench vice. And they all do something unique!
002.jpg



Update 3 - TIMELAPSE

Please watch this in at least 480p if you can, it goes pretty weird on anything lower.

YouTube- Project "Mars" - Update 3 - Timelapse


I call this the "RULER DANCE"..... *Dance*
 
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