Scratch Build

mrjack · 06-27-2009, 11:31 PM

While looking for a case for my next rig, I was somewhat disappointed by the cases out there on the market. Either a case was the wrong size, lacked features I was looking for, not available in my country or was simply too expensive to acquire. So I'm giving some serious thought to doing a scratch build, aka making my own case.

Some features I want to incorporate:
• lots of space
• cable management, not just to improve airflow but also looks
• efficient cooling, but also as silent as possible
• preferably made out of aluminum in order to keep down the weight
• removable motherboard tray

How I plan to do them:
• build a large case (duh), make separate compartments for the motherboard, power supply and hard drives (should also make the cooling more efficient)
• space between the removable motherboard tray and side panel, as well as space for running cables throughout the lower sections of the case
• use 120mm, or even better, 140mm fans
• made mostly out of aluminum, but will probably have some steel parts for stuff like sturdy HDD racks
• two or three bars vertically across the top section of the case with a sheet of aluminum, which has the standoffs, attached to them

At first I thought of using 120mm fans with 3-way switches for operating the fans at 12V, 5V and turning them off. But then it struck me. If at all possible, I should look into getting bigger fans, just because they run at lower speeds while still pushing a lot of air and being quiet. My current design would allow for installing 12 hard drives, while still having a lot of space left over for installing the motherboard and other components.

Most parts will hopefully be easy to make. Just cut the aluminum to proper dimensions and bend 90°, which they should be able to do at the store where I buy the aluminum. The ends of some of them will have to be cut to the shape of a wedge. Then just drill holes for the screws and fasten the parts together. Quite a bit of rubber will be going into the case as well in order to remove as much vibration as possible from hard drives and fans.

I'll post more SketchUp sketches as soon as I can, but I'm going to have to update my design a bit before I do that.

I have some questions though:
• Has anyone done anything similar before?
• Do you have any ideas for the backplate, buy one or try to build one?
• Any ideas on how to make the front panel of the DVD-drive fit into the case? The case will have brushed aluminum panels attached on to the frame of the case.

I've been thinking about trying to make a brushed aluminum front panel, but it's going to be tedious work making it attach to the drive sled. Any suggestions or links to forum threads or guides on making front panels for DVD-drives?

dak1b · 06-27-2009, 11:49 PM

great design! looks like ull have a cool system!!!!

**bomberboysk** · 06-28-2009, 01:57 AM

Might want to think about doing a double motherboard backplate, about 1-2" apart with the motherboard try held on with bolts. Would help with cable management.

mrjack · 06-28-2009, 08:47 AM

Quote:

Originally Posted by dak1b

great design! looks like ull have a cool system!!!!

Thanks. Hopefully it'll come out good and nothing major goes wrong.

Quote:

Originally Posted by bomberboysk

Might want to think about doing a double motherboard backplate, about 1-2" apart with the motherboard try held on with bolts. Would help with cable management.

Thanks for the suggestion. I was thinking of having some space between the motherboard and bars that hold it in place or between the bars and side panel. This would allow me to run the cables along the bars with zip ties.

blue957400 · 06-28-2009, 09:34 AM

If you do manage to build it and post up some pictures maybe you'd like to build another and sell it....(preferably to me...=]) depending on how it comes out...Paint i not a problem either because that would be up to me...

mrjack · 06-28-2009, 10:37 AM

I'm currently designing one for using 140mm fans, which is probably going to be the design I go with in the end. Due to the case being designed for using 140mm fans, the size has increased.

Quote:

Originally Posted by blue957400

If you do manage to build it and post up some pictures maybe you'd like to build another and sell it....(preferably to me...=]) depending on how it comes out...Paint i not a problem either because that would be up to me...

I think the case would have to be transported disassembled, if I were to make another batch of parts. I'd be more than willing to share the specs, if anybody is interested, once it is done.

Update:

Here is where I'm at with the 140mm fan version.

The main hard drive compartment section is basically two wind tunnels with a 140mm fan at one end and hexagonal mesh at the openings. The front panel will have a opening with hexagonal mesh with two 140mm fans blowing air in. Like in the earlier sketch, six additional hard drives can be mounted just behind the two fans in the upper compartment. The DVD-drive will be placed above the fans and I'll probably do something like what's described in this guide to hide the DVD-drive.

I'd love to get a Bulgin Illuminated Vandal Resistant switch for the power button, but they're expensive considering the purpose (15-20€).

EDIT:

Further update.

EDIT:

Further update, again.

Nevakonaza · 06-28-2009, 06:12 PM

That case is going to be awesome,Be sure to post pics!

Where you putting the power switches/Leds?

What software you use to do those drawing? Looks cool.

**bomberboysk** · 06-28-2009, 06:23 PM

For the bottom hdd's and fans like that, did you get your inspiration from the Tj07? What kinda finish are you thinking about doing on it, brushed aluminum or possibly black powdercoat? Be sure to post pics though, should be epic.

mrjack · 06-28-2009, 07:16 PM

Quote:

Originally Posted by Nevakonaza

That case is going to be awesome,Be sure to post pics!

Where you putting the power switches/Leds?

What software you use to do those drawing? Looks cool.

Thanks, I'll try to get loads of pictures. Good thing my brother is home, I should be able to use his digital camera to get some decent pictures.

The power switches are going just under the front panel fans. I was thinking of making a custom reset switch out of a momentary push switch, a spring and an acrylic cylinder that has the hard drive activity LED just on the side of it. The reset switch should therefore light up and blink properly. I'll have some designs of the reset switch up soon.

I'm not sure what I should do about the power LED. This'll probably be the power switch, a Bulgin MP0027, though if I can I'll get the Bulgin MPI002 with the blue led. I'll probably put a quick connector on middle of the cables between the switches and LEDs and their respective headers. That way I can leave everything installed on the motherboard and not have to fumble around with 'em trying to figure what goes where or whip out the manual every time.

I use Google SketchUp just because it's free and simple to use.

Quote:

Originally Posted by bomberboysk

For the bottom hdd's and fans like that, did you get your inspiration from the Tj07? What kinda finish are you thinking about doing on it, brushed aluminum or possibly black powdercoat? Be sure to post pics though, should be epic.

Can't say I'm familiar with the Tj07, I'll have to check it out. I've been thinking about going with brushed aluminum. I think brushed aluminum provides a simple yet elegant look.

Also, has anyone sleeved the cables of a power supply? I'd like to get an estimate on how long it takes to do so.

EDIT:

Latest one, just about to put in a motherboard and the motherboard tray to see how it looks. Then I'll start working on the backplate. I've also added a backplate for the power supply to help keep it in place. And a hole in the bottom of the case, just under the power supply so that it can take in air.

Also, a prototype (I made in about 5 minutes) of the reset switch.

Basically it is a momentary push switch mounted in a small box. In front of that is an acrylic cylinder that gets thinner and a spring to hold the cylinder in place. On the side is a LED next to the acrylic cylinder, which should light up. Hopefully the design is feasible.

Bootup05 · 06-28-2009, 09:50 PM

Mrjack is going to post!

Oh, LOL I didn't know you were the OP!

06-27-2009, 11:31 PM	#1 (permalink)
mrjack VIP Member Join Date: Jul 2005 Location: Finland Age: 18 Posts: 2,595	Scratch Build While looking for a case for my next rig, I was somewhat disappointed by the cases out there on the market. Either a case was the wrong size, lacked features I was looking for, not available in my country or was simply too expensive to acquire. So I'm giving some serious thought to doing a scratch build, aka making my own case. Some features I want to incorporate: • lots of space • cable management, not just to improve airflow but also looks • efficient cooling, but also as silent as possible • preferably made out of aluminum in order to keep down the weight • removable motherboard tray How I plan to do them: • build a large case (duh), make separate compartments for the motherboard, power supply and hard drives (should also make the cooling more efficient) • space between the removable motherboard tray and side panel, as well as space for running cables throughout the lower sections of the case • use 120mm, or even better, 140mm fans • made mostly out of aluminum, but will probably have some steel parts for stuff like sturdy HDD racks • two or three bars vertically across the top section of the case with a sheet of aluminum, which has the standoffs, attached to them At first I thought of using 120mm fans with 3-way switches for operating the fans at 12V, 5V and turning them off. But then it struck me. If at all possible, I should look into getting bigger fans, just because they run at lower speeds while still pushing a lot of air and being quiet. My current design would allow for installing 12 hard drives, while still having a lot of space left over for installing the motherboard and other components. Most parts will hopefully be easy to make. Just cut the aluminum to proper dimensions and bend 90°, which they should be able to do at the store where I buy the aluminum. The ends of some of them will have to be cut to the shape of a wedge. Then just drill holes for the screws and fasten the parts together. Quite a bit of rubber will be going into the case as well in order to remove as much vibration as possible from hard drives and fans. I'll post more SketchUp sketches as soon as I can, but I'm going to have to update my design a bit before I do that. I have some questions though: • Has anyone done anything similar before? • Do you have any ideas for the backplate, buy one or try to build one? • Any ideas on how to make the front panel of the DVD-drive fit into the case? The case will have brushed aluminum panels attached on to the frame of the case. I've been thinking about trying to make a brushed aluminum front panel, but it's going to be tedious work making it attach to the drive sled. Any suggestions or links to forum threads or guides on making front panels for DVD-drives? __________________ Intel Core 2 Duo E7200 @ 3.45GHz \| MSI P7N Zilent 2x2048Mb OCZ Titanium 800MHz DDR2 Western Digital Caviar 160Gb SATAII Samsung Spinpoint F1 320Gb SATAII Western Digital Caviar 500Gb SATAII Samsung Spinpoint F1 750Gb SATAII MSI NX8800GT OC 512Mb Creative Sound Blaster X-Fi Xtreme Audio Antec Truepower Trio 550W Windows Vista Ultimate 64-bit

06-27-2009, 11:49 PM	#2 (permalink)
dak1b Gold Member Join Date: Jul 2007 Location: California Posts: 266	great design! looks like ull have a cool system!!!! __________________ CPU:Intel Core 2 Duo E6850 Conroe 3.0GHz RAM:CORSAIR 4GB 240-Pin DDR2 HDD:Seagate Barracuda 750GB 7200 + External 640gb drive MBO:NVIDIA nForce 750i GPU:GeForce 9800 GX2 1GB PSU:PC Power & Cooling 750W CASE:Thermaltake Armor+ MONITOR:Acer Black 22" + vizio 42" hdmi dual monitor setup =] KEYBOARD: G15 Gaming/Logitech G5 2 Mouse OS: Windows Vista 32bit

06-28-2009, 01:57 AM	#3 (permalink)
bomberboysk Moderator Join Date: Jan 2008 Location: Northeast Ohio, But mainly infront of computer Age: 16 Posts: 8,062	Might want to think about doing a double motherboard backplate, about 1-2" apart with the motherboard try held on with bolts. Would help with cable management. __________________ CPU: Intel Core 2 Quad Q9450 @ 3.90Ghz Custom Water Loop \| Mobo: EVGA 790i Ultra SLI \| GPU: 9800gtx and GTS250 in SLI\| Ram: 4GB(2 x 2gb) 1333Mhz ddr3 \| Case: Xclio WTBKAdvanced \| Sound: X-fi Fatal1ty Championship, Z-5500 5.1 Surround\| HDD: 2x Raid 0 7200.11 500gb \| PSU: Zalman ZM-1000HP \|OS: Windows 7 Enterprise x64\| Dont skimp on a power supply,if it fails, it usually takes out other components alongside it. New? Dont forget to read the rules, Know them so you dont break them:) My Heatware

06-28-2009, 09:34 AM	#5 (permalink)
blue957400 Silver Member Join Date: Apr 2009 Location: California Posts: 204	If you do manage to build it and post up some pictures maybe you'd like to build another and sell it....(preferably to me...=]) depending on how it comes out...Paint i not a problem either because that would be up to me... __________________ _________________________________ Case: Coolermaster Elite 330 Motherboard: GA-P35-DS3L CPU: Intel Core 2 Duo e6750 @ 2.66ghz RAM: OCZ Gold 800mhz GPU: PNY Geforce 8800gts 320mb XLR8 PSU: Coolermaster 550 Watt HDD:250gb Sata Monitor: Acer X223w Speakers: Logitech Z-560

06-28-2009, 06:12 PM	#7 (permalink)
Nevakonaza VIP Member Join Date: Oct 2005 Location: UK Age: 21 Posts: 12,748	That case is going to be awesome,Be sure to post pics! Where you putting the power switches/Leds? What software you use to do those drawing? Looks cool. __________________ Desktop= Core 2 Quad Q6600 GO @ 3.4Ghz\|MSI P35 Neo-F\|[5GB OCZ Vista Gold Series -6400 oc.\|XFX HD 4890 XT 1GB GDDR5 \| X-Fi Xtreme Fidelity 7.1\|Coolermaster Dominator 690 Black (Modded)\|OCZ ModXStream Pro 600w Modular\| 250Gb & 500GB Sata2 Avermedia Volar HDTV Tuner\|Windows 7 Home X64 Asus X58 Laptop Intel M575 2Ghz \|120GB Sata HDD \|Crucial 2GB DDR2 800mhz \|15.4 inch Widescreen display]\|Intel GM965\|Vista Basic 32Bit\|DVD-RW

06-28-2009, 06:23 PM	#8 (permalink)
bomberboysk Moderator Join Date: Jan 2008 Location: Northeast Ohio, But mainly infront of computer Age: 16 Posts: 8,062	For the bottom hdd's and fans like that, did you get your inspiration from the Tj07? What kinda finish are you thinking about doing on it, brushed aluminum or possibly black powdercoat? Be sure to post pics though, should be epic. __________________ CPU: Intel Core 2 Quad Q9450 @ 3.90Ghz Custom Water Loop \| Mobo: EVGA 790i Ultra SLI \| GPU: 9800gtx and GTS250 in SLI\| Ram: 4GB(2 x 2gb) 1333Mhz ddr3 \| Case: Xclio WTBKAdvanced \| Sound: X-fi Fatal1ty Championship, Z-5500 5.1 Surround\| HDD: 2x Raid 0 7200.11 500gb \| PSU: Zalman ZM-1000HP \|OS: Windows 7 Enterprise x64\| Dont skimp on a power supply,if it fails, it usually takes out other components alongside it. New? Dont forget to read the rules, Know them so you dont break them:) My Heatware

06-28-2009, 09:50 PM	#10 (permalink)
Bootup05 Diamond Member Join Date: Jan 2006 Location: South East England Age: 18 Posts: 2,652	Mrjack is going to post! Oh, LOL I didn't know you were the OP! __________________ Intel Q6700 @ 3.66GHz Gigabyte UD3P P45 6GB DDR2 800MHz Asus 4890 @ 950/4500 750GB Samsung Spinpoint - 320GB WD Caviar - 160GB Seagate USB Belinea 26" Wide LCD SoundBlaster Live 24bit USB - Acoustic Energy Aego M Thermaltate Ultimate Extreme Back in Push Pull Tagan 600W 48A Quad Rail Win 7 x64 RC Last edited by Bootup05; 06-28-2009 at 10:07 PM.

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