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Fractal-Design Define XL "Custom Motor Coach"

post #1 of 47
Thread Starter 
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Hey guy's here is a build log for the Fractal Define XL case I have been commissioned to do. The case was graciously donated by Fractal-Design.
This will be only a case build with no PC hardware,that will be installed by the end-user.
It will be loosely based on the 2007 Corvette Brickyard Pace car mainly for the paint scheme. Goal is to give it an automotive feel without modifying the entire case as most of the mods will be done on top section of the case.
It will include CNC billet aluminum case feet,headlight and taillight bezelsand polished stainless exhaust side pipes. I will also make the lens for the lights out of cast acrylic with 12 volt LED bulbs. Grill opening will be fitted with modders mesh donated by MNPCTECH. Window will be shipped with clear acrylic that can be used or easily used as drill template for different color acrylic.
Table of contents:
1. Day one,cover plates.
2. Top rad cover.
3. Rear filler ,grill cutout and welded up.
4. Window cutout.
5. Body side moldings and exhaust

OK on to the build:
Here I have roughed out a set of case feet from 2" stock aprox. 1 1/2" tall with final design yet to be determined.

Fractal005.jpg

Fractal007.jpg

Inside I made couple cover panels just to help clean up the inside.

Fractal004.jpg
Fractal008.jpg

Now to set it up for 360 rad in the top panel,as most of you know there isn't enough room in most cases for rad and push/pull fan setup. So I bent up a piece of .070 thick stainless because it is the same thickness of the rad grill I'm going to use. I used a sheet metal roller to create the radius in the front.

Fractal001.jpg
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Fractal003.jpg
Edited by FannBlade - 11/22/12 at 7:23pm
    
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post #2 of 47
Sploosh
post #3 of 47
Thread Starter 
Ok let's see if I can get everyone caught up:
My first thought was to just make some straight panels to fill in the sides but wanted to do something different. I needed 2 1/4" to fill in top panel so ordered up some tubing.
At this point I still had no direction of completed project...just started build and let it come to me.

Fractal016.jpg
Fractal017.jpg
Fractal019.jpg
Fractal021.jpg
Fractal022.jpg
Fractal024.jpg

Now to cut out case top.
Fractal025.jpg
Fractal027.jpg
Fractal028.jpg

Time to cut out for the rad grill. This is one I had here off an old build and used it mainly because it's steel. Both the new top and grill are .070 that should give it a nice flush look.
Fractal030.jpg
Fractal032.jpg
Fractal033.jpg
Fractal034.jpg
Fractal035.jpg
Fractal036.jpg
Fractal037.jpg
Fractal038.jpg
    
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post #4 of 47
Thread Starter 
Today I made the rear filler panel and cut out the grill area and finally welded top panel in place. Excuse the dirty welds I was out of argon gas so used a flux core wire. YUK!
Fractal039.jpg
Fractal040.jpg
Fractal041.jpg
Fractal042.jpg
Fractal050.jpg
Fractal052.jpg
Fractal054.jpg
Fractal055.jpg
Fractal056.jpg
Fractal057.jpg
    
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post #5 of 47
Thread Starter 
Now onto the window cutout. Layed out with masking tape and cutout with angle head grinder with 4 1/2" cutoff wheel and corner finished with a dremel.

Fractal062.jpg
Fractal065.jpg
Fractal067.jpg
Fractal087.jpg
Fractal089.jpg

Drilled and installed the 8/32" nutcerts for the cover panel

Fractal081.jpg
Fractal085.jpg

First round of prep work done. 4 rounds of bondo work rough down to 180 grit. I will be using a 2 part filler primer to final it for paint and wet sand with 400 grit paper.

Fractal090.jpg
Fractal091.jpg
Fractal092.jpg
    
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post #6 of 47
Thread Starter 
Another update:
I got the case feet tapped for 10/32 bolts and drilled case so I could get them mounted. This let me layout for the exhaust side pipes. Once in position drill through holes and attached them with 4- 8/32 nut-certs and some stainless bolts. Pipes with be sanded with 1000 grit and polished to a chrome like look.

Fractal097.jpg
Fractal099.jpg
Fractal101.jpg
Fractal102.jpg
Fractal103.pg
Fractal105.jpg


Also started playing with the stainless body side moldings,still haven't decided if I will use these yet but do have them ready for final finish work.

Fractal109.jpg
Fractal110.jpg

Pic of the modders mesh for the grill area donated by MNPCTECH.
Fractal106.jpg
Edited by FannBlade - 11/10/12 at 4:33am
    
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post #7 of 47
lookin really good. Subbed. biggrin.gif
post #8 of 47
Killer.. A fellow bondo user. /salute
post #9 of 47
Thread Starter 
Quote:
Originally Posted by Johnsen View Post

lookin really good. Subbed. biggrin.gif
Thanks

Quote:
Originally Posted by AlderonnX View Post

Killer.. A fellow bondo user. /salute
Bondo can fix anything!!
    
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post #10 of 47
I have been wanting to mod cases all my life, but never have had the machinery to do it. How much did it cost for you to acquire all the machinery needed to perform what you are doing right now?
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