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Author Topic: Project: Aluminum Water Cooling Case  (Read 42401 times)

Spotswood

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Project: Aluminum Water Cooling Case
« on: June 06, 2011, 10:33:01 PM »

This is a project/build log for an aluminum case designed specifically for a large water cooled rig.  This case is capable of housing:
  • 3 x 140x4 radiators
  • 1 140x3 radiator
  • 10-slot motherboard tray
  • A boat load of 5.25-inch drive bay devices






The basic frame of the case consists of .5x1-inch u-channel with its ends plugged with blocks press-fitted and pinned with a #4 screw along with some 1-inch angle:












The assembled case frame is too tall to fit in the camera frame.  hehe





The frame looks kind'a "meh" until I bolt on the gorgeous anodized quarter rounds.






The two shelves were cut from a .10-inch thick 5052 via my trusty router, a straight edge and a downcut spiral bit.




At the back corners of the shelves, two .5x1-inch cutouts were routed out via a temporary router jig.






The rounded inside corner left by the .5-inch flush router bit were filed square.




FWIW, here's the difference in the thickness of the aluminum sheeting I use (.10-inch) compared to what everyone else uses (.063).




A mockup of the shelf inside the frame of the case:




A local fabricator cut the 5.25-inch drive bay rails for me. 




A 140x4 rad arrived here in the shop.






Thanks for looking.  Stay tuned!

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Rich

urgannagru

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Re: Project: Aluminum Water Cooling Case
« Reply #1 on: June 07, 2011, 10:59:16 AM »

It's looking good  :thumbsup: I can't wait to see more.
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Glitch

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Re: Project: Aluminum Water Cooling Case
« Reply #2 on: June 09, 2011, 05:27:49 PM »

Already interested  ;)
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Spotswood

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Re: Project: Aluminum Water Cooling Case
« Reply #3 on: June 09, 2011, 06:02:17 PM »

Next up is to cut the front sheet.




In order to cut-out all of the openings for the 5.25-inch drives accurately, a custom router template is required.  I used .5x1-inch u-channel and .25x1.25-inch flat bar to frame the openings on .5-inch particle board.




The aluminum bits guided my flush trimming router bit.




The aluminum bits were removed and the particle board template was used to cut the .10-inch thick aluminum sheet.






Now I just need to square all of the corners and cut to final dimensions.  Ugh.
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Rich

Spotswood

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Re: Project: Aluminum Water Cooling Case
« Reply #4 on: June 26, 2011, 03:07:21 PM »

"Life" had gotten in the way of this project for a few weeks, but I've managed to fabricate the inner and outer sheets of the front panel.  It took me 5 hours to square-off all of the inside corners.

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Rich

Spotswood

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Re: Project: Aluminum Water Cooling Case
« Reply #5 on: July 02, 2011, 10:04:18 PM »

Back sheet cut to width, height and the hole for the 10-slot motherboard tray routed out.







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Rich

Spotswood

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Re: Project: Aluminum Water Cooling Case
« Reply #6 on: July 10, 2011, 07:42:25 PM »

The inner and outer front sheets, cut to final length.






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Rich

Spotswood

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Re: Project: Aluminum Water Cooling Case
« Reply #7 on: July 15, 2011, 07:20:36 PM »

Shelves!


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Rich

Spotswood

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Re: Project: Aluminum Water Cooling Case
« Reply #8 on: July 17, 2011, 09:05:48 PM »

The 5.25-inch drive bay rails:









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Rich

Spotswood

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Re: Project: Aluminum Water Cooling Case
« Reply #9 on: August 06, 2011, 01:38:05 PM »

I bolted the 5.25-inch drive rail assemblies to the front inner sheet.






Note how the extra deep rails will completely hide the drives and cables.






Another design benefit of the front air duct is hiding all of the mounting hardware.





 
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Rich
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