The Intelligence - Day 10
If I'm ever gonna start painting this thing I need to get all of the mock-up and fabrication done, so I started doing the stuff I have been putting off.
removed all the remaining case hardware including the feet and the Zero-H id tag and serial number. This took over an hour since everything was riveted to the case and had to be drilled out. The feet needed their own special set of steps:
-drill hole in rivet from inside of case
-cut a cross pattern in the head of the rivet using a dremel cutoff disc
-squeeze the cross cut inwards using pliers
-whack the rivet with a hammer
-pry foot off with a flathead screwdriver from the outside of the case
rinse, repeat * 4
drilled the pilots for the intake fans (sorry bright)
having learned from the holesaw issue from other day, I devised this method of supporting the case correctly for holesawing the intake openings...
much better and way more stable than the other day, and I didnt end up with incomplete cuts this time, and no jumping drill, etc. When the cuts were done I just filed them a bit with a half-round
increased the screw holes from the pilot size to their actual size of 3/16
needed to get the mobo pan anchor screws done. I drilled thru the pan and rails with 6-32 drill bit, then tap threaded the rails with the pan removed (this pic is not indicative of what I just said above - I started to tap thru the pan but realized it was silly)
after I tapped the rails, I drilled slightly larger holes in the pan, so the screws pass thru, and screw into the rails, this is the test fit.
then on the rails I JB-Welded some #6 washers around the holes I just tapped. This will rise the pan flush with those srew heads. I did this on all three rails, but only two are pic'd
apparently ZH doesnt fully glue the case channel all the way around the case, so I ended up with a couple of places where I had to jb-weld it back in place. I guess it isnt ZH's fault, it was fine and sturdy as a camera case, but not so after having been cut up to fit a computer inside
welded
and this part, same deal, loose channel and another piece completely off...
jb welded and clamped. I keep forgetting to get some small clamps to keep in the shop...
so I made Make-shift Clamp Support - Version 1.0 Stepping A0
Once the psu arrives I can jbweld the L brackets and rail spacers in their final places. Then on deck is to mount the hdd and dvd supports.
Thanks for watching
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