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(Build Log) Project: Forest Fire - Page 2

post #11 of 15
Thread Starter 
First:
I got a 1 to 1 printout of the adapter plate for the chassis of the case, when i taped it up, and stuck my fans/rad in place, i quickly realized the screw holes were misaligned.

they weren't misaligned by a great amount and luckily all the holes were off by the same amount (from the printout). within CAD, the screw holes were referenced from the center point of the circle, so the original measurements made, were roughly 1/16th inches off, thus it cascaded down.

a quick fix in CAD and were ready to rock, soon as this is done, I'll get a final quote of everything, and the machining will be started / completed within the day (so they say) LOL

Second:
I also decided to dremel out the flames on the side cut-out, I been recently practicing with my dremel, and i got a really super awesome, tungsten carbide milling bit, tried it out this last weekend and it cuts through some old aluminum i had lying around like a hot knife through butter, and very easy / accurate to use. I'll have to be careful on the sharp edges, this thing like to round things off pretty fast tongue.gif

Third:
I also decided to get something i thought i wouldn't need, but i got one of those Aquacomputer aquaero 5 PRO. I decided to get one, mainly because i want to be able to control all my fans, calculate flow, and temps in/out of Rad(s). not to mention i really love the idea of having a fail safe, the controller will shutdown the PC, if a critical error occurs.

in my case it would be pretty good to know if say i had a serious issue, and all that $$ hardware is "saved."


obviously its not a 100% fail safe, but it may just come in handy and with this being my first custom water cooling build, I will feel much safer.
post #12 of 15
Thread Starter 
I got one of my panels back, the machine shop is done measuring it, and will hopefully be cut very soon, but in the meantime, I did a bit of cutting myself!

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The Above image is my first cut i did, and is the front of the panel

The Below is the backside of the cut

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finally the effect I was hoping for the entire time, which I'll get in this later in my post

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The shadow effect!

The main reason i wanted to do a cut out is for a shadow effect, I plan to achieve this with some lighting of course, and different color of acrylic, I thought of doing an EL Panel, but I don't think it would have the effect i am looking for.

My final goal with the cut out is having a multi-colored "flame" effect on the wall parallel to this panel, which is roughly 5 feet away, so it should give off a decent sized shadow effect if done correctly.

I got more cutting to do, so far i got 2 flames cut out, and sanded down to roughly 100 grit, I want to get to at least 400 grit and all flames cut out by the end of this weekend.

That is tons of work though! the flame I posted here took roughly 3 hours, so it is a very tedious process, but in the end it will look awesome!
post #13 of 15
Thread Starter 
I got the cut outs complete, got them done last weekend, I just haven't updated this build log yet.
I also sanded them down to 200 grit, (I want to go to 600 at least) so I obviously have some more sanding to do.

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Probably the most difficult cut out was the top middle flame, it was very small intricate turns and grooves, and even the most experienced dremel user would have a hard time imo.
Luckily patience is a good virtue to have
I now wish I took pics of the actual process, but no worries!
How I actually cut these out, I used a couple different steps…
1. Trace out the flame, I used my dremel and lightly grazed the area I wanted to cut, I used my Carbon Fiber cicular cutter, but you can also use an engraver.
2. Cut in layers and sections, do not cut through a small section and drive it around your trace!
Step 2 means once you have a nice trace, simply make your traces deeper and deeper in certain sections, my sections were to specific points within the cut out mainly from one intricate turn/groove to another. Layering the cut, means make 1 pass between that certain section, until you’re about through the material, DO NOT cut through the material! Move onto the next section, I did this because if you completely cut through one fine point like a sharp edge you’ll have a very difficult time cutting the other part of the sharp edge.
3. Once you have all the sections layered out to roughly the same depth, I cut through the easy parts of the cut first, as I was getting closer to the more difficult parts, my suggestion is go very slow and layer it down until you cut through. You don’t have to cut through all parts as long as it is barely held together, and once the cut is done, simply push it out.
4. Now that the piece is cut out, I used an end mill, this will give you a nice clean looking edge, you shouldn’t have to put much pressure on the material, the objective is to get rid of the jagged stuff, and form the curves.
5. File things down! Filing things down, again forms the curviness to the cut out, and shapes the sharper edges, you can use some elbow grease and really get those nice looking edges and curves, and of course filing things down, removes any burrs you might still have, and preps it for sanding.
6. Sand, sand, sand, and sand some more!

Total time it took to do all this on each cut out was roughly 14 hours, (200 grit sand paper) – so I’m not completely done yet, but the hard parts are done.


One thing I forgot to mention is the shadow effect i am looking for...

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this is a grainy pic, and the fact my 2 and 1/2 year old daughter was holding the light tongue.gif but you can still get an idea of what I'm looking to do.

I will need to focus, and adjust the height of the case once it is complete, that and i can do some cool stuff to focus it more with the acrylic, - or so I'm told. LOL

Next weekend I will be taking a “modding break” LOL I will be going fishing with my cousins for the weekend, should be lots of fun!
Machine shop update though pieces are all ready to be made, I’m just waiting on them now.
post #14 of 15
Thread Starter 
I got a few things back from the machine shop!

First I'd like to show the side panel

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imo that side panel is starting to look great! next thing for the side panel is layering some acrylic and using the lighting properly to make it pop!

I didn't put a pic of the shadow of the side panel because no pic i took gave it a hint of what it actually looks like in person, so I will need to get a much better camera than what i have on my phone!

but when i used a flashlight up to the wall, it looks amazing!
so i can't wait until i get it all complete and see the final product.

I decided to put the 80mm fan grill on one of the exhaust fans
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Below is another piece i had the machine laser cut out, was my holes for the pumps, again i will putting a piece of acrylic behind the cutout, with two holes drilled into it to change the speed of the pumps if needed.
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Finally the one thing I hope every is impressed as much as i am!

I am speaking of my super secret mod i have talked about all along!

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RAM Heatsinks that are FLAMES!

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A special thanks goes out to HybridChiller who made this possible!

I currently have just one, this was a prototype, but it looks great and fits perfectly, I still need to do some filing, but not big deal.

eventually it will be painted, along with the rest of the case.

minus some smaller things the next big updates will be sleeving, assembly, and acrylic for the pump cover, and side panel.

Hope you all enjoy!
post #15 of 15
Thread Starter 
Update:

Sleeving!

But first!

my messy work area filled with sleeving, and a bunch of junk every where else!

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You may be wondering why, do you have combat green in there!? WTH?!...

once you see the finished product you'll see a transition, from flames to green. this is signifying the movement of forest fire

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The Blue tape is to know which wire is which, for my MB RST, PWR, and HDD + / - leads.

Word to the wise: if you decide to sleeve your switches, your PWR, and RST, will most likely be the same color, (mine are yellow) they are connected to a 2 pin, but have individual leads on the other end, so know which wire / side of connector you pull. Luckily I knew this already but I would hate for people to blow anything up from a overlooked mistake like that.

Hope that will help future sleevers smile.gif


I also painted 3 of my fans also sleeved them

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Hope you enjoyed it!
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