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Thermoelectric ~ 800D Case Mod (Over 1m tall!)

post #1 of 73
Thread Starter 
Thermoelectric
(a fitting name) My main PC build ~ a large vertical case extension to house a new thermoelectric cooling system and custom watercooling loop.

I'm working on a lot of different stuff with my PC at the moment, specifically this should cover my thermoelectric cooling adventures and all the changes to my case which happen in that time.

A picture of the build so far standing over 1m tall:




So as much for my own sanity as anything else, I'm putting together a list of plans, materials and logging my work from the start instead of normally just taking a load of pics and never uploading them.


The Plans:

~ Liquid Cooling
~ ~ New Radiators (9th June)
~ ~ Parallel reservoirs (30th June)
~ ~ Perspex has arrived (12th July)
~ ~ Starting on the main waterblock (25th July)

~ TEC Cooling
~ ~ The power supply arrives (26th May)
~ ~ Block designs sent to a plastics company (27th June)

~ The Case
~ ~ 5 pages in and work on the actual case mod starts (25th June)
~ ~ Basic framework completed (1st July)
~ ~ Radiator mount completed (2nd July)
~ ~ Framework Sprayed (4th July)


The Materials:

~ Aluminium Plate for waterblock (received)
~ Rubber cord for sealing waterblocks (received)
~ 2 Black Ice GT Extreme 480 radiators (ordered)
~ 12 Gentle Typhoon 2150s (ordered)
~ 1 900W PSU (30V 30A) (received)
~ 2 64mm 400W Qmax TEC units (received) ~ Ordered two 270W Qmax ebay TECs to test the water
~ Copper Sulphate for electroplating the waterblocks (received)
~ Laser Etched 800D Side Panel (received)
~ 2 170 x 100 x 10mm Pieces of acrylic for the waterblock (unordered)

The Tools: (I'll be using a lot of tools, but the ones I have/will be buying for this project)

~ Dremel (received)
~ Sandpaper for lapping all the heat transfer surfaces (received)
~ Tap and Die Set & (received)
~ 11.8mm Drill Bits (received)
Edited by Crabid - 7/25/11 at 12:13pm
    
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post #2 of 73
Thread Starter 
Liquid Cooling

Having looked at the pump requirements for glycol at subzero temps I have decided on a direct die approach to TEC cooling the system, using 2 64mm TECs.

The hotside waterblock designs:







The base is a pin matrix design, the middle section will be used to more evenly distribute the flow across the whole of the matrix to keep the whole surface of the TECs cool.

Also, since this is aluminium, which will cause galvanic corrosion, I will be electroplating the waterblock and other heat transfer surfaces in copper.

To cool the massive heat load coming off the TECs and to make sure all of that heat is dumped from the loop efficiently, I will be using two Black Ice GT Extreme 480 radiators in series. The pump will be a Swiftech MPC35x and depending on the restriction of the loop when I get all the parts to have a play with, I may get another MCP 35x.

My graphics card will have it's own separate loop using a 360 radiator in the case.
    
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post #3 of 73
Thread Starter 
TEC Cooling:

I will be running two 64mm 400W Qmax TEC Units in series.

They will be running on a 30V 30A PSU and cooling a 40mm piece of plate aluminium which will act as a direct die block to the CPU.
Edited by Crabid - 5/8/11 at 1:51pm
    
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post #4 of 73
Thread Starter 
The case

While being huge, the 800D isn't nearly big enough to house 2 480mm radiators and a large PSU.

To address this, I will be increasing the height of the case by around 12".

In this top section I will be housing:

2 x GTX480 radiators
12 x Gentle Typhoon 2150rpm fans (from here)
1 or 2 MPC35x Pumps
1 900W Power supply for the TECs (30V 30A)


The side panels of the case have already been laser etched with this design:




I've hooked a red NZXT LED strip light up to the inside of the side panel to illuminate the etching:






Following this, I will be getting another panel etched to be a front window to the extended top section.

I will also be sleving all of my cables and tidying the cable management in the back of my case extensively:
    
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post #5 of 73
Looking good mate
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post #6 of 73
Thread Starter 
Here's the metal I got for my water block and direct die block.


All solid aluminium, large piece is 40mm alu plate, others are 3mm.





I want to get a serious plan developed for the extension on top...

I'l try and book out some time to kill on stetchup, it's just hard with Chimpin on, my CPU is flat out on folding and doesn't take kindly to modelling...
    
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post #7 of 73
Quote:
Originally Posted by Crabid View Post
The case
Seriously when i saw this no lie the only thing in my mind was... woaah.
post #8 of 73
Thread Starter 
Quote:
Originally Posted by Gawdz View Post
Seriously when i saw this no lie the only thing in my mind was... woaah.
In a good way I hope ^-^

Little update today, picked up a few more bits:

11.8mm Drill bits to makes holes for...



...my BSP 1/4 tap, to make my own fittings for waterblocks.




Also, I got my copper sulphate for electroplating:



And a load of rubber for making O-rings in the custom waterblocks.



There's also some rubber glue and a 10m strip of neoprene I'm going to use for insulating the cold side of the block.
    
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post #9 of 73
Thread Starter 
Little update, added the base to my block designs:







Still need to work out if it'll fit though.
    
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post #10 of 73
Amazing I say.


Electroplating what with what?

I hope you aren't copper plating the aluminium... It will make a galvanic cell and the aluminium will corrode (not only corrode, it will make salts that will grow in size over time), making the copper plating gently sweep away from the alu block. In matter of hours.

Aside from that (I want to hope you have that covered), it's gonna be epic dude. Tremendously epic.


Subbed for sure. I've taken chemistry concerning Red-Ox reactions, electrochemistry and so on, so if I can help in anything concerning the platings, give me a call.
   
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