Not as easy a thing to do as I was thinking it would be. Part of the problem being I can only work on it durring the weekend and I usually like doing other things durring the weekend. If I only had a garage, I could use the shop to do certain things and then do the rest at home, but I have an apartment with noise rules, so working at home is out. The shop is at my work and there is too much going on from 7am till midnight for me to use it durring the weekday and only working on it durring the weekend is taking forever for everything to come together.
The computer hardware I will get into later. This is a case build from scratch and that is mostly all I am focused on for now. The case will be 24" wide by 24" deep by 30" tall. It is split up into 3 sections, with the top being a horizontally mounted motherboard. It will have 9 MCR320 radiators, 8 MCP355 pumps (4 XSPC res tops, 4 non res tops), a shit load of 120mm fans and fittings. 4 loops: CPU gets 2xMCR320, VGA 1 gets 3 MCR320, VGA 2 gets 3 as well and 4th loop is for NB/SB whatever and gets 1 MCR320. Or I may do something completely different, but there will be at least 4 loops.
I am not a metal worker. I am not a craftsman. I have access to the shop and some knowledge on a few things, but this is not my normal gig. I am winging it through alot of what I did here. My planning was very loose and I wish I would have spent more effort on it, because it is now costing me alot of effort to work my way around problems I could have avoided. Anyway, onto some pics.
There is more, but it's just the same stuff...more rads, pumps, etc.
http://img383.imageshack.us/img383/248/img0475cd4.jpg
Here is a sheet of .063" thick 6061 T6 bare. It is 4'x8' and really scratched up as well as quit a few gouges. I can fix/hide these, but no way I make this a bare aluminum finish or even anodized. It will have to be painted. I like black, but that's been done to death. Doesn't mean I won't paint it black, but I am open to other colors....although only dark colors...maybe plum red....some kinda deep blackish red.
http://img402.imageshack.us/img402/6188/img0481op0.jpg
This is a table shear. It cuts aluminum sheets very well
http://img402.imageshack.us/img402/7123/img0483hu8.jpg
http://img402.imageshack.us/img402/5957/img0485bx8.jpg
Got some 1/2" angles to form the edges on the panels. Cut em up with 45 degree ends on this meiter saw I got at Home Depot for $20.
http://img402.imageshack.us/img402/7765/img0520dc3.jpg
Layed out on a front/back panel
http://img402.imageshack.us/img402/8895/img0523ro4.jpg
http://img234.imageshack.us/img234/9706/img0524hy4.jpg
Drilled a couple holes with a hole saw
http://img234.imageshack.us/img234/8342/img0547hj9.jpg
http://img234.imageshack.us/img234/8945/img0527ve0.jpg
http://img234.imageshack.us/img234/3464/img0528sg6.jpg
Layed out my side panels, measured it out and then cut the side panel into three sections. I was going to have a TEC chiller build in this and the bottem section was going to house the hot side of the TEC, so I made a section to isolate it from the rest. I have now decided a TEC chiller is not worth the effort and won't be doing it, but the section was already cut so the case will be put together as if I were needing the bottem rads, sectioned off. Who knows, maybe I will do a TEC chiller after a while, even though everything shows that it is a worthless pursuit.
http://img234.imageshack.us/img234/1576/img0535bh3.jpg
Drilled fan holes for the sides using the front panel as a templat
http://img234.imageshack.us/img234/9011/img0545jj4.jpg
Rad holes done.
http://img234.imageshack.us/img234/6610/img0548nm4.jpg
Worked on angles for the front and back panels
http://img234.imageshack.us/img234/3974/img0551fv6.jpg
http://img234.imageshack.us/img234/3471/img0552mj6.jpg
Countersinks for all holes I will be riveting through
http://img234.imageshack.us/img234/162/img0579xh2.jpg
These are flush rivets. Many here are probably familier with the blind rivets. These are actually much bigger then the ones I used..otherwise it's exactly the same. It's just my camera sucks at close ups, so I just got the biggest flush rivets we had and took a pic.
http://img234.imageshack.us/img234/20/img0719tx5.jpg
You install these rivets either with a rivet gun and bucking bar. Using the bucking bar to press against the tail end of the rivet as you jack hammer the head of the rivet with the rivet gun till the tail buckles and locks the rivet in place
http://img234.imageshack.us/img234/7238/img0583jh3.jpg
Or you squeeze it with a rivet squeezer...although you are limited to only edges as the squeezer can't reach anything else
http://img234.imageshack.us/img234/4452/img0720aw5.jpg
http://img234.imageshack.us/img234/6122/img0723xd9.jpg
There's a rivet in between each cleco. Tried getting a close up pic, but non came out very well. With some sanding, I doubt even a blind person can feel the rivets while running their fingers over it.
http://img234.imageshack.us/img234/8155/img0722ud8.jpg
Tail side
http://img234.imageshack.us/img234/171/img0586wf0.jpg
http://img234.imageshack.us/img234/9599/img0727fd9.jpg
http://img234.imageshack.us/img234/8567/img0700it2.jpg
http://img234.imageshack.us/img234/7955/img0701kr4.jpg
http://img234.imageshack.us/img234/7425/img0702aw2.jpg
http://img234.imageshack.us/img234/2733/img0703jg9.jpg
Ok, that's it for now. Next weekend I work on angles for the sides and maybe panels for the different sections. I ordered two 5x5.25" drive bay's from Mountainmods and once I get those, will see about placing it on the front panel and if I like it, will make the cuts to install em. For a PSU, I have a 1600watt Ultra X3 and as great looking as I think that PSU is, I will be making a larger PSU box for it and will gut the X3 and fit it in my larger box with 2x120mm fans. I also need to come up with a way to make all the side panels for the rads swing open like cabinet doors, so that I can have access to those areas without having to take things apart everytime I need to get in that area. This build is getting more difficult then I anticipated. I was thinking I was just building a big box lol