Project: PrometheusCU - Update #1 - Dec 3rd 08

[SaibotC]

Sponsored by:
AquaComputer


Watercool:


MIPS Computer GMBH


Corsair


This is my first real desktop mod, and it's been long in planning. Now that most of my components have arrived and some progress has been made I've decided to share what I've created so far.

The concept behind this case is to design a simple elegant case jam packed with technology, toys, and a powerful watercooling setup.

The idea for the design was directly inspired by the case I started with, a 10th Anniversary Lian-Li PC-a60c: *click for big*




First I'll outline the system components I'll be using:

Main System
Lian-Li PC-A60C 10th Anniversary #294 of 300
Silverstone Strider 1200W Modular ATX
AMD Phenom X4 9850 BE Quad Core AM2 2.5GHZ
Corsair Dominator PC2-8500 5-5-5-15 8GB (4x2GB)
ASUS AM2+ M3N-HT Deluxe Mempipe 3-way SLI
2x EVGA E-geForce GTX 280 SSC 648MHZ 1024MB 2.322GHZ

Secondary System
VIA ARTiGO Kit A1000 C7 1GHZ 1GB DDR2
OCZ 1GB DDR2 SODIMM PC2 PC-5400 667Mhz
Fujitsu 2.5" IDE 5400RPM 120GB
XDX 7" VGA Touch Screen TFT LCD 1024x768

Router/Firewall
PCEngines ALIX.2C1 Kit 3x10/100LAN
SparkLAN WMIA-207GN WLAN 802.11n Mini PCI
1GB Type 6 Compact Flash

Storage/Media
Pioneer Slim 8X DVD+/-RW Slot Load
Slim CD/DVD-ROM to SATA Adapter
4x Hitachi 3.5" SATA 7200RPM 750GB
3x LaCie Neil Poulton eSATA 7200RPM 750GB External
Lian-Li Aluminum 50-in-1 Card Reader

Additions
Mini Nova USB Bluetooth Adapter
Zalman Plus Multi Fan Controller
Matrix Orbital GX Typhoon USB TRI-LED LCD 240x64
2xNexxtech mini 4 Port USB Hub
AquaComputer multiswitch USB 1.41
AquaComputer aquaero 4.00 USB

Air Cooling
6xScythe Ultra Kaze 120mm x 25mm 133.60CFM
1xScythe Kama-Flex 80mm x 25mm 34.0CFM
9xScythe Mini Kaze Ultra 40mm x 20mm 4.86CFM

Watercooling
Aqua Computer Aquastream XT Ultra USB Eheim 12 V
Feser XChanger Triple 120mm Xtreme
D-TEK FuZion V2 Socket AM2 Waterblock
D-TEK FuZion v2 Quad Core Mid Chamber Insert
Mips Ram Freezer 4 Ram Waterblock Nickel Edition
2xAquaComputer G200 waterblock for GX280
AquaComputer Durchflusssensor (Flow Sensor)
6xAquaComputer Rotary elbow adapter G1/4]AquaComputer aquaero/aquastream XT temperature sensor 70 cm
Danger Den Cooling System Fillport Black
Primochill Primoflex Pro LRT Black 1/2IN ID 3/4IN OD Tubing
20x Bitspower G1/4 High Flow 1/2IN Dark Nickel Plated Barb Fittings


Here is a rough concept of the design plans: *click for big*



I'm sorry I diddn't take any progess pics so-far but I'll be doing so from here on out.

[Langer]

After a few hours with the dremel and jigsaw... then many more with a set of hand files I turned my lian-li case into the below:


The details:
First I cut out some material from the drive bay area


I then mounted the Alix 2c1 embedded linux firewall after installing the mini-PCI wifi-n card and the 1GB compact flash

A cutout was made to allow space for the lan ports on the motherboard tray. Also a box was cut from the drive bay to allow for the pump to be mounted.

I haven't yet built the pieces that will guide the airflow; but i have installed the fans that will cool the Alix board.

1/4inch slots will be milled on the panel and dividers will be constructed to guide the air out the slots. Until then, this is how it stands.

Here is the Pump


And the mounting bracket put into place


Two 120mm fan holes were cut from the top of the case



A large rectangle was removed from the front panel to make space for the 7" touch panel LCD

[Langer]

I then built another temporary bracket to hold the PSU in place. This too will be replaced with a CNC machined bracket.





After cutting a piece of copper plate that will 'compression' fit into place. I used double sided foam tape to afix the slot load dvd-rw.

I then installed the slim-DVD to SATA adapter.


The drive is then squished into place, and holds suprisingly well


Then the pump is mounted to the bracket, this foam is also temporary and will be replaced with black neoprene


We then come to the Pico-ITX unit that will live in the drive bay



Here is is installed



I then cut apart the Corsair Dominator fan assembly and made some temporary mounting brackets, the final brackets will be CNCd as well.




The zalman fan controller that I'll be using


Here is the fan contoller installed


The final fan assembly and some glamour shots




I also got a Lian-Li card reader, it will be stripped of its case by the end of this mod

[Langer]

Here is the radiator I'll be using:


The cutout I made, where it will live. I still have to make mounting brackets for it.





This is where the hard drive bay will mount



But first these need to be installed. Again these are only temporary, for fitting purposes, the final peices will be made from copper plate and will be CNC machined.






Now we can suspend the drive cage





And finally we come to the below images. This is how Project PrometheusCU sits right now, waiting on delivery of some of my watercooling components.



As it stands I'm at about 30% complete.

Hope you all enjoy the work... I've poured pretty much everything I have into this case - in terms of both skillsets and money.

Please feel free to leave comments, crits, suggestions.

Tune in soon for more!

[Langer]

Let us begin.

I've finished the rad mount prototype.

I started with a 40"x40"x1/8" sheet of used aluminum.
This panel was once used in the fabrication of Carbon Fiber sheets - the aluminum panel are used to help form the carbon panel. The carbon is cooked in a heated press at ~40,000tonnes. After a short while, about 100 carbon panels, the aluminum develops imperfections and heat stains - It's then thrown away. My Dad runs the Carbon Fiber plant so over the years I have developed a rather large collection of these aluminum sheets.


After a bit of rough cutting with the trusty jigsaw I did some light filing to clean the cuts.


Then onto bending


The final product, minus the holes.


Once that was complete I checked the fit - luckily the "measure 5-times cut once" methodology continues to work for me.


A side view, note also that the final bends will be much more precise. I plan on having 'V' shaped groves milled into the copper plate where bends are needed to ensure accuracy.


Then I had to drill precise holes in the the chassis.


From there I did a test fit. (Note that the final design will include slots for airflow, I'll post an illustration later today.)
Almost perfect, I eyeballed the holes in the rad mount prototype and a couple were off slightly. No big loss though because the final product will be machined precisely.


Thanks for reading! More to come.

[Langer]

Another update for you guys, but there will be more to come this weekend.

I've finished the tray prototype that will both house the radiator, and lift Prometheus 3.5" off the ground.

We again start with some aluminum plate. As you can see I've marked out the areas to be cut.


Like the above post, I've put the jigsaw to work.


After using the dremel to crudely score the bending lines I put the piece in my bending brake.
This is what I came up with


A close-up of the joints.



Then a test. Perfect Fit!





And here is how it sits right now.
In fabricating these parts I've realized that the final design will need to seat the radiator about 1/4" lower. As you can see from the pics, I haven't left enough room for the front rad fan to breathe.
But that's why I made these prototypes... to narrow in on design flaws such as that.



That's all the fabricating I'll be doing today, tune in later I'll have some illustrations posted.

Thanks for reading!

[Langer]

A small update for the masses.
Here is an idea of what a couple of the copper components will look like.
From left to right - Front Facade Panel, Top Exhaust Fan Grill, Radiator Grill/Mount. I'll post the designs for the rest of the pieced some time tomorrow; along with some of the illustrations that I'm going to have engraved throughout the case.

black = cut
grey = engrave
dashed = bend
*click for supersize*

Added a a 'jagged edge' to the front facade. Since the touch panel LCD covers the traditional front air intake I will need to mill slots in the side of the front panel to act as air intake. The jagged edge will make space for these intake slots. The slots can be seen in the initial design concept illustration

Thanks for reading! Tune in soon for more.

As always, crits are welcome and appreciated.

[Langer]

Small update

Black lines = cut
Grey lines = engraved
Dashed lines = bend

Here is my concept for the plaque replacement on the back of the chassis


I've also completed the concept for the drive bay enclosure (the piece seen taped into place in this image).

I modified the original design to encase the lower 3.5" drive bays, and allow for a fill point (nearly forgot about that).
*click for supersize*

[Langer]

Here is the accumulation of all the final part concepts that I'm going to be milling from Copper plate.
(as always, click for supersize)

1: Drive Bay Enclosure - Left Side


2: Drive Bay Enclosure - Right Side


3: Authenticity Plaque


4: Front Facade


5: Bottom Tray/Radiator Housing


6: Parts List Plaque


7: Radiator Fan Grill/Mount


8: Top Fan Grill


9: Front Lower Tray/LCD housing


Enjoy!

[Langer]

Parts update for the masses:
I recieved a package of watercooling supplies today.
First up - a D-Tek Fuzion rev 2 with quad core nozel insert (insert not installed in below images).



FeserOne Orange non-conductive coolant, I'd have preferred black but since I'll be using black tubing and no reservoir I don't see the difference... and neither will anyone else, hehehe.



20x Bitspower Hig Flow 1/2 barbs - dark nickel plated edition.

Here you can see the difference between the Bitspower fittings and the stock DangerDen and D-Tek ones.


A Black DangerDen Fillport


Last but most certainly not least... 15' of Opaque Black Primochill Primoflex 1/2ID tubing.

I was quite surprised by the width of the wall, I guess I don't have to worry about puncture leaks... too much.


That's all for now folks, tune in soon!