Project: Ultra

[AVT]

PROJECT:
ULTRA

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Good morning, everyone!

Now that I've begun the cutting, it's time to post the worklog.

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Information:

This is a project to build a custom case that fits into Delta Airlines' carryon luggage limit, and, for me, does absolutely everything. I'm naming it 'Ultra' for no reason, except for the fact that the word 'Ultra' is quite awesome.

Features:

• Size: 320x200x430 mm
• Full-ATX
• Watercooled
• Powdercoated flat black (no fingerprints! )
• No extra room for components I'm not ever going to use

Full Specs:

• CPU: Intel Xeon E3110
• Motherboard: Biostar TPower i45
• Video: XFX 8800GS (may upgrade)
• Sound: X-FI XtremeMusic (will be modded for better sound)
• RAM: 4gb Corsair DDR2-800 DHX
• PSU: Corsair HX520W
• HDD: WD VelociRaptor 150gb
• DVD: Toshiba-Samsung slimline combo drive
• Radiators: Swiftech MCR320QP + MCR120QP
• Fans: 4x Yate Loon DS12M @ 5v (should be ~600-800rpm)
• Pump: Laing DDC + XSPC Res Top
• Waterblocks: D-Tek Fuzion, D-Tek Fuzion GFX

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Sketchup:

Huge thankyou to all the people at the Sketchup Components Collection for posting their stuff!

The model:

Some of the items in the screen are different than what I've got, but the sizes should be the same. As you can see, I'm a Sketchup newb, so it doesn't look too pretty, but hey, at least the sizes are accurate.

Cuts&bends:

I could not find a model of Lian Li's motherboard trays, so cuts for it it weren't drawn here. The aluminum will be cut based on measurements from the actual tray. The same is true about the radiator, but for a different reason - the measurements on the model are slightly off.

The whole case needs to be cut by Thursday, when I'll be taking it to have it bent, and after that, to powdercoating.

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Comments?

 

[mrmylanman]

You're gonna have to empty out that water loop if you carry it on :-P

 

[Logan321]

And then fill it back up with bottled water on the plane... or vodka, or w/e.

 

[AVT]

You're gonna have to empty out that water loop if you carry it on :-P

Correct - this is why I went with the XSPC ResTop - it should make filling/draining/bleeding very simple. For the same reason, I'll be using pure distilled water with iandh Silver KillCoils in the tubing rather than adding PT_Nuke.

All in all should take me an insignificant amount of time to refill compared to disassembling and rebuilding the rig - the next best option.

 

[mrmylanman]

Sounds good. You thought this out pretty well. I can't wait to see some progress on it, I like to see some more compact systems out there.

 

[AVT]

Stage 1 of cutting complete. I'll sand/file.. tomorrow.

Hopefully will have time tomorrow to take it to a shop for bending. Radiator/tray & other mount cutting, in addition to all drilling, will be done after that.

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Total cost thus far: $23
$9 - aluminum from local bulk metal supplier
$14 - 10x now-broken reinforced Dremel cutting wheels

 

[voklskier4452]

with the way it looks like you will be going through cutting wheels.. i suggest you get a nice jigsaw and some metal cutting blades

they are soooo much easer to work with

 

[AVT]

with the way it looks like you will be going through cutting wheels.. i suggest you get a nice jigsaw and some metal cutting blades

they are soooo much easer to work with

Yeah, I do wish I had one, even though the Dremel@30K rpm cuts through aluminum like a knife through bread. Not as fast as through butter, though.

I'll probably end up buying one if I ever get involved with more crazy projects after this. Not now, though - the bulk of the cutting is done.

 

[AVT]

Case has been taken to be bent. Estimated costs are $107=$45 planning+$4.50/bend.

More expensive than I expected, but fits into the budget of $350 on the metal. Would have cost a LOT less if I didn't need 180* bends for attaching the side panel.

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Total cost thus far: $130
$9 - aluminum from local bulk metal supplier
$14 - 10x now-broken reinforced Dremel cutting wheels
$107 - bending

 

[AVT]

If anything can go wrong, it will.

Looks like the place that sold me the aluminum sold me aluminum that isn't bendable, EVEN THOUGH I specifically asked about this when purchasing. Additionally, the brake that the place I took the aluminum to for bending cannot two of the bends because their machinery would hit the aluminum, so, they've offered to weld it together instead & grind it down, which IMO is actually an even better solution.

Thus, everything needs to be re-cut. But hey, at least I was too lazy to file it and didn't waste my time on that (I can't believe being lazy actually pays off for once )

New cuts&bends:

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Total cost thus far: $23
$9 - aluminum from local bulk metal supplier
$14 - 10x now-broken reinforced Dremel cutting wheels

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Comments?

 

[AVT]

Big-ass update coming - get ready!

Case has returned from bending.

Even though my aluminum turned out to be unbendable, they found another piece that was bendable, cut it, bent&welded it, made an extra side-panel (which I unfortunately won't be able to use, see later), and charged me less for it than was originally quoted. Will DEFINITELY be returning to them for welding of the PSU cage and front panel. If you're around the San Diego, CA area and need any such work done, check out their website at http://millermarine.us/

The case, before any of my work.

The welding is nice and smooth. Aside from the color difference, it's almost impossible to even tell it's been welded from the outside. There's scratches, but what's wrong with that, it's going to be powdercoated anyway.

Welds are much more visible from the inside.

Side panels will be attached here. The 180* bend ensures that the side panel will not stick out from the case. My original design had the aluminum slightly longer, and a 180*+90* bend on the side panel, but this actually works out even better since I can drop the 180* bend.

The other side of the case.

Here's the side panel that they made as well. Those big marks are from a pencil, not scratches.

The side panel on the case.

Here's the reasons I can't use it. Firstly, it leaves about 1mm extra room above it when it's attached.

Second, there's a ~0.5mm gap between it and the other sides of the case. Unfortunately, this is aesthetically not acceptable. Attention to detail.

Here's how it looks on the bottom of the case. The side panel that will be used will look exactly the same.

A mockup of how components will be placed inside.

edit: There used to be a bunch of pictures here showing cutting out of the mounting holes for the radiator, but I've removed them. Reason: I just took the radiator off, and I'm not satisfied with how the holes turned out. Will re-do them tomorrow on the other side. Thankfully, all cuts currently made will have no effect whatsoever after the that side's cut out as the areas around them will all be cut out - each one.

That's it for today! Will be cutting with the dremel very soon. Total cost has gone down, as it only accounts for costs that are actually used in the final.

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Total cost thus far: $85
$85 - aluminum/cutting/welding

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Comments?

 

[shadowlord]

look very interesting so far !

keep up the good work!

 

[AVT]

@shadowlord: Thanks!

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Getting ready to draw measurements.

All measurements drawn.

Dremel engraving attachment used to ensure accurate drilling.

Spare fan pulled from an Apevia junk PSU used to ensure holes are properly spaced.

All holes drilled.

Test fit. 4/12 holes are good.

Test fit #2. Size of holes increased from 5/32 to 3/16. All but 3 holes are fine.

Rest of holes grinded outwards to fit, using a Dremel tile-cutting attachment.

Cut via Dremel.

Should be fairly accurate.

Test fit. Can you see the problem?

Oh no! I cut a little too far. Will have to take it to welding to be patched up later. Worst-case scenario I can just have the whole panel re-cut and re-welded on. And that's the downside for making the case from one big piece - screwing up is ten times as bad.

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Total cost thus far: $85
$85 - aluminum/cutting/welding

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Comments?

 

[AVT]

Wasn't home for much time today, so not that much progress, but all drilling/cutting concerning mounting of the motherboard tray have been made.

The holes, cut. All match up perfectly, as expected, since they were cut from the de-riveted panel.

The finished job. I'm very happy with how it turned out. The pencil line will be cut off and welded at 90*, since I couldn't manage to get it to bend properly. Oh yeah, and I was just kidding earlier, two of those holes from the original radiator drilling will need to be patched up. Only two, at least.

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Total cost thus far: $85
$85 - aluminum/cutting/welding

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Comments?

 

[Logan321]

Maybe it's a crazy idea but why not put the rad on the outside of the case, and the fans inside? it'll cover your hole that was cut a little too big, most likely. You'll just have to drill a couple holes for the barbs to go through.

OR for the front, get a piece of aluminum bent like \____7 (imagine the top of the 7 attaches to the face of the case, hiding the mounting hardware, and the flat part covers over the fans or radiator, if you choose to switch 'em) You could even cut yourself or get CnCed whatever kind of design you want as a fan grill.

 

[kencheeto]

Also, if you get a 3x120 rad grill w/matching holes, depending on the design it could very well cover up the cuts. Just make sure your screws are long enough to go through case -> rad grill - > rad

 

[AVT]

@Logan321: My primary purpose towards covering up the cuts is actually not aesthetic, but functional. Air will bleed through them as-is, reducing performance. They're very hard to see unless you know they're there.

I may actually move the radiator outside, if 10.5" video cards won't fit with it inside, which, as of now, looks like it may possibly happen, as the distance seems to be VERY tight. I'd rather keep it inside as I'd have to make the front panel bigger to accommodate the radiator.

That's exactly how the front panel will be set up, with modder's mesh over the fans.


@kencheeto: The main problem with getting a grill is that it's going to add to the case's overall thickness, and things are already very tight inside.

 

[AVT]

Another (short) update!

Finally got some rivets and riveted the tray onto the case.

Oh no! The 120mm radiator won't fit with the rivets - side panel will get in the way. Thus, it will have to be welded on.

Prep'd for welding.

Took it back to the shop again today. They told me they'll be able to do almost all the welding, but can't patch up my bad radiator cuts as it would cause the metal to warp. Therefore, I will have to cut a new piece to be welded onto the case in place of the current one. They also provided me a new piece for free. If you're around the San Diego, CA area and need any such work done, check out their website at http://millermarine.us/ - very good people.

Good thing I didn't cut holes for the optical drive yet.

Will be cutting again as soon as I get the time, hopefully sometime this week. No estimate yet on how much the second welding will cost me.

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Total cost thus far: $85
$85 - aluminum/cutting/welding

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Comments?

 

[AVT]

FWIW project is NOT dead, will be updated soon. I've been busy with, uh, another project. May have some pics of that too.

 

[Arcygenical]

Please do.

Custom cases always excite me

 

[AVT]

Please do.

Custom cases always excite me

Thanks for the encouragement!

Was supposed to update everything the day after I made the last post, but instead spent the day looking for a new pair of sunglasses. Will hopefully take pictures today.

Anyway, here's one of the things I've been working on: a replacement for my old HTPC where the whole project basically went south, and has now been sold for parts. I call it Project: Ion.

The SketchUp:

The case would be built similarly to how this one is: from aluminum, welded together, and powdercoated.

It'd be built around Zotac's Ion board, with a Slimline Slot-loading Blu-Ray drive (ofc, the drive pictured isn't slot-loading, but my sketches are never accurate ). Would use a ~8gb or similar SLC SSD for the OS, and a 2.5" HDD, hotswap, for storage. Still debating as to whether do this and swap HDDs, or build a separate rig purely for storage, store it somewhere where noise won't matter, and connect via WiFi. The HDD would be off when not in use, and the whole system should be completely silent.

I'd like to start building it ASAP, but realistically, sometime in August if not later. Project: Ultra has to be finished before I start Project: Ion.

That's one of the things I've been working on. Will update with another one hopefully today - that project has been started & finished in the time this one's been on hold.

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Comments?

 

[ekuest]

definitely cut your holes small and then take them to the lines with a rough file. and finish it off with a fine file. makes for better accuracy, and nicer finish. cool case you got going, ill be watching this once you get it going again.

 

[AVT]

definitely cut your holes small and then take them to the lines with a rough file. and finish it off with a fine file. makes for better accuracy, and nicer finish. cool case you got going, ill be watching this once you get it going again.

Later on, I will. Right now it doesn't make much sense considering I could always screw up and have to cut the entire side off, make another, and have it welded back on.

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Anyway, I was supposed to start this again soon after posting earlier, but other things inconveniently got in the way. Project has started up again, though. Small update for today. Will hopefully cut replacement front tomorrow, and PSU cage on Friday.

Case has returned from welding. Unfortunately, the powdercoating people tell me that I'm going to need to take it back to get a continuous weld with the tray. However, front panel and PSU cage will need welding as well, and the side panel needs 180degree bends, so those will be done before I take it there.

First hole for 120mm radiator is drilled. Sorry about the blurry pics.

Perfect?

Second hole drilled.

All four drilled. Turns out first one wasn't perfect after all.

Holes increased to 3/16, and everything's fine.

Radiator cuts finished. Unlike the 3x120mm radiator's cuts, these are good.

OK, that's it for today. Time for some cookies and homemade cherry soda.

Yes, that's homemade cherry soda. The other project mentioned above was this. Thankyou to those who made this site - the soda machine, as I like to call it, works great!

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Comments?

 

[AVT]

Another update!

I was going to cut the PSU cage as well, but unfortunately the aluminum I have isn't big enough. Will need to go buy more, hopefully tomorrow.

Thus, again, small update.

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This is the replacement front for the one I f'd up earlier. Here's it's measured. Realized I forgot to take pics in the middle of cutting, so stopped and took one.

Cut. No need to file, the only rough sides will be welded anyway. The bottom (in this pic) part will be bent at 90 degrees, and will help the side panel stay on.

Test fit. So far, it looks good.

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Comments?

 

[AVT]

Very short update!

Lots and lots (probably ~20hrs) of work done, but not at home. Huge thankyou to a friend named John (who is in the construction business) for helping, especially with the PSU cage, and with getting my new bending brake working!

As of right now, I've got about 9hrs until I'll be on an airplane flying to San Francisco, and still need to sleep. Unfortunately this means I neither have time to explain some of the clever solutions we came up with to various dilemmas, nor show pictures of my new bending brake and all the problems we ran into with it. I'll update it when I get back, which isn't until August 1st. Sorry.

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The finished PSU cage. Cut via skilsaw, bent via 18" bending brake, tabs bent with.. I'll call it trickery. Next update will show the solution we came up with.

Will be welded here. Taking it tomorrow, right before the plane. Thank goodness the welding place is pretty close to the airport.

With PSU. Horizontally, it's a perfect (maybe even too perfect? I hope powdercoating doesn't ruin it) fit. Vertically, we have 1/8" clearance, within tolerance.

A picture from the other side. Note that it is about an inch longer than necessary, as I don't yet know the exact length the case will turn out after the front is re-welded on. It'll be cut and a front tab bent then.

The front panel. It'll also be welded on. Fans will be inserted from the bottom, and the front grill will be easily removable from there as well.

The replacement panel I screwed up earlier. Note that the bend radius in the center is slightly greater than around the edges - this is a limitation of my bending brake. I intend to take care of it permanently later, but couldn't yet.

The bend radius difference was originally massive, but we found a way to reduce it to these levels, which are acceptable. The radius is about 1/16" greater in the center. Originally, it was about 1/4" greater.

This piece will be welded onto the top.

The front has been cut out of the case. The new one will be re-welded on.

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I'll update more when I get back - my flight back is on August 1st.

Comments?