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Ad Infinitum: 15-Bay Server Build

post #1 of 11
Thread Starter 
Well, first worklog, very exciting! This will be a case mod for a home server, because I'm currently too chicken to really mod my main PC. Given that I plan to have it chugging away 24/7, a name like Ad Infinitum seemed appropriate, plus it gave me a reason to make an (admittedly simple) logo:

picture.php?albumid=4341&pictureid=25415

I'll be using unRAID and some of its addons. I'm not currently in desperate need of tons of space, but my project to rip the family DVD collection has begun to pick up steam, and I anticipate that expandability will be helpful. I figure space for 15 drives (28TB usable space, using all 2TB drives with unRAID) should be plenty for a while.

At the moment, the only piece of the puzzle I've yet to acquire is the case, I'll be using one of Sharkoon's budget-ish 9 5.25' bay cases, you can see pictures below.

The internals are:
Motherboard: ASUS M4A78LT-M LE
CPU: AMD Sempron 140
RAM: 2GB (2x1GB) Kingston DDR3
Controller Card(s): 1x SUPERMICRO AOC-SASLP-MV8, 1x Silicon Image SIL3132
HDDs: 3x Hitachi Desktar 5K3000 (starting small)
PSU: Antec Neo Eco 520W

I'm using 3 NORCO SS-500 hot-swap modules, as seen in the stock photo below:
ss500ff.jpg

And I'll be using either the Sharkoon Rebel9 Pro Economy:
rebel9_pro_eco.jpg

Or the Sharkoon T9 Economy:
T9_ECO_02_1.jpg

Both have the same basic cable routing cutouts and black interiors.

The list o' mods for this project is:

1. Modify the drive cages to support 92mm fans. As they are, the hot-swap modules support an 80mm fan, behind the back piece. I'll be removing the grill, enlarging the fan cutout, and adding new mounting holes for 92mm fans. The mounting holes for 80mm fans will likely remain, just in case. FINISHED!

2. Bend back/grind down/cut off the 5.25' bay support tabs, they get in the way of the hot-swap modules.

3. Add top exhaust fans to the T9 (only if I go with the T9, obviously).

4. Remove mesh fan grills from existing fan mounts.

5. Install an acrylic side window. This is more for experience than anything else, as I doubt there's much interest in viewing the server internals.

6. Add a few more cable routing cutouts, mostly for front panel header cables.

I'm currently waiting on my case, and for the rest of my server internals to make it over here.
Edited by Alecthar - 7/8/11 at 5:17am
post #2 of 11
Thread Starter 
Reserving for Table of Contents (when/if needed) and any other fanciness.
post #3 of 11
Excited for this.
    
CPUMotherboardGraphicsRAM
AMD Phenom II 965 Black Edition ASUS M5A97 GeForce GTS 240 Kingston 4GB 1600 mhz 
Hard DriveCoolingMonitorKeyboard
Western Digital WD Black WD1001FALS 1TB 7200 RP... Antec Kuhler 620 Samsung LED 23" SyncMaster S23B300 Razer Blackwidow Ultimate 2013 Elite Mechanical... 
PowerCaseMouse
Thermaltake Smart M Series 850w Modular Cooler Master Storm Scout Razer Taipan Gaming Mouse 
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CPUMotherboardGraphicsRAM
AMD Phenom II 965 Black Edition ASUS M5A97 GeForce GTS 240 Kingston 4GB 1600 mhz 
Hard DriveCoolingMonitorKeyboard
Western Digital WD Black WD1001FALS 1TB 7200 RP... Antec Kuhler 620 Samsung LED 23" SyncMaster S23B300 Razer Blackwidow Ultimate 2013 Elite Mechanical... 
PowerCaseMouse
Thermaltake Smart M Series 850w Modular Cooler Master Storm Scout Razer Taipan Gaming Mouse 
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Reply
post #4 of 11
Defo gonna be watching this one smile.gif
HTPC
(13 items)
 
  
CPUMotherboardRAMHard Drive
Intel i3-540 (3.06GHz) Zotac H55 A-E 4GB OCZ DDR3 10666 LowVoltage 250 GB WD 2x 1TB F3s, 1 2TB F4 
Optical DriveOSMonitorCase
None Windows 7: Ultimate x64 LG 42LD450 Fractal Design Array R2 
  hide details  
Reply
HTPC
(13 items)
 
  
CPUMotherboardRAMHard Drive
Intel i3-540 (3.06GHz) Zotac H55 A-E 4GB OCZ DDR3 10666 LowVoltage 250 GB WD 2x 1TB F3s, 1 2TB F4 
Optical DriveOSMonitorCase
None Windows 7: Ultimate x64 LG 42LD450 Fractal Design Array R2 
  hide details  
Reply
post #5 of 11
Thread Starter 
Quote:
Originally Posted by The Architect;13736805 
Excited for this.
Quote:
Originally Posted by KingCuddles;13736840 
Defo gonna be watching this one smile.gif

Thanks to you both for the encouragement!

I did forget to mention a couple of things in the OP. I'll be removing some toolless mechanisms from the 5.25' bays, but that's not necessarily a "mod," and my plan is to have a scaled up version of the logo I included in the OP laser etched into the window, which I plan to get through Pedgette. I'm thinking maybe smoked acrylic, because with all the SATA cabling going on inside this thing it won't be winning any "Rate My Cables" threads. Lower visibility might be my friend.
post #6 of 11
Thread Starter 
Wow, okay, so like a month has gone by since I posted this. Between work and an unexpected (but good!) change in living arrangements, I didn't have much free time.

So, when I moved in I broke the modules down a bit:

CagesBrokenDown.jpg

When I finally got the chance to take care of modifying the HDD cages, I visited my parents (my father's a pretty avid carpentry hobbyist) and borrowed my dad's drill press and spindle sander. Naturally the press was for the fan screw holes. I just used some pretty basic cutting tools to take out the fan grill, roughed out the rest of the blowhole with a file, then finished it with the spindle sander. They came out pretty well overall I'd say:

ModdedCages.jpg

CagesOut.jpg

ModdedRearView.jpg

The holes were originally going to have u-channel molding around the edges, but it forced the fan just far enough away from the back piece that it caused a fitment issue, so the edge is naked.

I should be picking up the case later this week. Will update with details when I get the chance.
Edited by Alecthar - 7/5/11 at 5:49pm
post #7 of 11
Looking forward to seeing where this goes biggrin.gif

subbed and good luck
post #8 of 11
Thread Starter 
Quote:
Originally Posted by frizkie;14119120 
Looking forward to seeing where this goes biggrin.gif

subbed and good luck

Thanks! I feel like I'm going to need it.

And it's also "I already regret something!" time:

So, with the way I cut the fan holes, the fan housing is actually either very close to, or actually is, resting on some kind of battery in on the SATA backplate PCB. Obviously, this isn't ideal, but I assume it won't hurt anything. I should have kept and used the bottom-right 80mm screw hole and used it, drilled the rest of my holes, then done the cutout around that, and just gone with a square without its corners type cutout (not sure a better way to describe that). It would have ensured that I cleared that battery and left me without any of the grill or screwholes for the 80mm fans. The fan would have been slightly off-center, but I doubt that would have significantly impacted cooling performance.
post #9 of 11
any updates ?
post #10 of 11
bump for updates
HTPC
(13 items)
 
  
CPUMotherboardRAMHard Drive
Intel i3-540 (3.06GHz) Zotac H55 A-E 4GB OCZ DDR3 10666 LowVoltage 250 GB WD 2x 1TB F3s, 1 2TB F4 
Optical DriveOSMonitorCase
None Windows 7: Ultimate x64 LG 42LD450 Fractal Design Array R2 
  hide details  
Reply
HTPC
(13 items)
 
  
CPUMotherboardRAMHard Drive
Intel i3-540 (3.06GHz) Zotac H55 A-E 4GB OCZ DDR3 10666 LowVoltage 250 GB WD 2x 1TB F3s, 1 2TB F4 
Optical DriveOSMonitorCase
None Windows 7: Ultimate x64 LG 42LD450 Fractal Design Array R2 
  hide details  
Reply
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