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[Scratch mITX Case] Project Al

post #1 of 47
Thread Starter 
Project Al

What is Al? Al is a mATX server chassis that will be able to house 1x ATX psu positioned in front of the motherboard, 8x 3.5" HDDs, 4x 120mm fans and 1x mATX Motherboard.

I am currently building a mITX chassis using similiar design/techniques before tackling the mATX chassis. Now for the good stuff.

The current plan is to use hardware I already have but if I can manage to sell a few things and gather up some extra scratch I will upgrade the hardware going into this. For right now the hardware list is:

Intel Atom Gigabyte GA-D525TUD
Pico-PSU 160w
I'll need to buy an SSD to pop in this thing. Probably something on the cheap end of the spectrum.
Delrin Illuminated Switch Black - 22mm Blue Ring
Delrin Illuminated Switch 16mm Black - Blue Dot

INDEX:
1. Tools arrive for tapping/drilling
2. And broken shortly thereafter
3. Got some new taps and went to work!
4. First prototype takes shape
5. Got some switches from Performance PCs
6. New design cut and bent with some glamour shots!
7. Top and bottom complete. 95% total done.
8. Testing LED Switches
9. Fitting the I/O shield
10. Mounting the SSD


mITX Chassis:




mATX Chassis:

Revisions being made, COMING SOON!

ph34r-smiley.gif
Edited by Shrimpykins - 1/9/13 at 6:31pm
 
Project Al
(69 photos)
 
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Project Al
(69 photos)
 
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post #2 of 47
hummm... This should be interesting...
CaveMonkey Rig
(15 items)
 
OldSchool Rig
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Ryzen 1700 MSI X370 Gaming Pro Carbon EVGA GTX980Ti Classified  2x8GB G.Skill TridentZ 3600 
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Sandisk 256GB M.2 SSD Crucial MX100 256GB Be Quiet Dark Pro 3 Windows 10 Pro x64 
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iiyama - ProLite XUB3490WQSU-B1 Ducky Mini Brown Switches Corsair RM850i Fractal Design Define R5 
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Opteron 175 DFI LanParty NF4 Ultra DR BFG 8800GTS 512MB OC2 (G92) 2x1GB DDR PC4000 GSKILL F1 
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Seagate 320GB 7200.11 SP Shythe Katana II WinXP Pro SP3 Duky Zero Red Swithes 
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EVGA 500W Lian Li PC-A05FNB Logitech G300 QPad 
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Q6600@3.2Ghz DFI P45 Lanparty Dark T2RS Plus XFX GTX260 2*2GB Crucial Ballistix PC6400 
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Kingston V300 60GB Zalman CNPS X10 Windows 7 x86 Dell 19'' 
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CaveMonkey Rig
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OldSchool Rig
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CPUMotherboardGraphicsRAM
Ryzen 1700 MSI X370 Gaming Pro Carbon EVGA GTX980Ti Classified  2x8GB G.Skill TridentZ 3600 
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Sandisk 256GB M.2 SSD Crucial MX100 256GB Be Quiet Dark Pro 3 Windows 10 Pro x64 
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iiyama - ProLite XUB3490WQSU-B1 Ducky Mini Brown Switches Corsair RM850i Fractal Design Define R5 
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Logitech G502 Proteus Spectre Qpad CT OldGents.se Creative SoundBlaster Z + Edifier Studio R1600T... 
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Opteron 175 DFI LanParty NF4 Ultra DR BFG 8800GTS 512MB OC2 (G92) 2x1GB DDR PC4000 GSKILL F1 
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Seagate 320GB 7200.11 SP Shythe Katana II WinXP Pro SP3 Duky Zero Red Swithes 
PowerCaseMouseMouse Pad
EVGA 500W Lian Li PC-A05FNB Logitech G300 QPad 
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Onboard 
CPUMotherboardGraphicsRAM
Q6600@3.2Ghz DFI P45 Lanparty Dark T2RS Plus XFX GTX260 2*2GB Crucial Ballistix PC6400 
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Kingston V300 60GB Zalman CNPS X10 Windows 7 x86 Dell 19'' 
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post #3 of 47
Thread Starter 
Santa came early and brought me some presents.



4-40 bottoming tap, 0.166" drill bit and a 0.089" drill bit as well as a tap and guide setup. The 0.089 bit is for the tap, and the 0.166 bit is for the press-in captive nuts. I was cutting the holes on a waterjet but it was not accurate enough and caused stress fractures in the aluminum when they were pressed in because the hole was slightly smaller than it needed to be. Now they are perfect.

Put to good use a few minutes later on some 0.25" aluminum.



The back side - NO HOLE!


The metal looks like crap because it's old scrap that has begun to corrode and is scratched up. This is just a test piece though. All final pieces will be finished or painted. I need to wait on some more hardware to continue with the tests. I am thinking of making a mITX case first to reduce material usage while I work the kinks out.
Edited by Shrimpykins - 12/21/12 at 2:50pm
 
Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
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OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
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Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
Hard DriveHard DriveOptical DriveOS
OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
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post #4 of 47
Thread Starter 


Was going smooth until I broke the tap:




Have to wait to get another now.
Edited by Shrimpykins - 1/5/13 at 1:17pm
 
Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
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OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
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Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
Hard DriveHard DriveOptical DriveOS
OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
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post #5 of 47
Nice.. I love hand made metal cases
post #6 of 47
Thread Starter 
Went and hit up the local hardware shop since Lowes/Home Depot don't carry 4-40 taps apparently. Half-day at work so I took the last half of the day to work on the case.

I had to cut a new back I/O panel. The mounts for the motherboard standoff and the screws that attach the motherboard tray to the back I/O panel ran into each other slightly (minor design flaw). Being so, I had to make a new motherboard tray as well so the pics below are totally new pieces compared to the pics above.

The piece attached to the standoffs is a piece I cut to represent a mITX motherboard without messing up an actual mobo out in the shop. The bend you see in it is just stress relieving from when it was cut and me not straightening it out.





The outside shell is designed, I am just double checking the dimensions and will be cutting it and bending it when I get the chance.

EDIT: Off topic, 2 more posts to the big 4k baby!

2nd EDIT: Been feeling cruddy all day, throat scratchy, no energy, etc. That's why I only did the tray and back pieces. After I got home I was able to take some meds, drink a lot of water, and rest for a while. I got a second wind and went back to the shop, got the rest of the case minus the sides cut.
Shortly after I ran out of captive nuts so I have go wait for those to finish it.
Edited by Shrimpykins - 1/5/13 at 1:17pm
 
Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
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OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
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Dayton Audio DTA-100a Asus Xonar STX 
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Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
Hard DriveHard DriveOptical DriveOS
OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
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post #7 of 47
Thread Starter 
Came down with something pretty nasty. Had a fever for two days that I managed to break last night. Been a crappy christmas.

I am just now getting over it so I guess things are looking better on the horizon. I did get 4 more packs of SS captive nuts ordered so I will have quite a few to play around with. Once those arrive I can get back to work.
 
Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
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OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
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Dayton Audio DTA-100a Asus Xonar STX 
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Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
Hard DriveHard DriveOptical DriveOS
OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
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post #8 of 47
Thread Starter 


Captive nuts!









More in progress, stay tuned.
Edited by Shrimpykins - 1/5/13 at 1:17pm
 
Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
Hard DriveHard DriveOptical DriveOS
OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
AudioAudio
Dayton Audio DTA-100a Asus Xonar STX 
  hide details  
Reply
 
Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
Hard DriveHard DriveOptical DriveOS
OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
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Dayton Audio DTA-100a Asus Xonar STX 
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post #9 of 47
Impressing metalwork. +rep for that

Subbed
post #10 of 47
Thread Starter 
Quote:
Originally Posted by WebsterXC View Post

Impressing metalwork. +rep for that
Subbed

Hey hey! Thanks for the rep and for subbing!

We are moving a lot of stuff around in the shop and the brake got messed with when it got moved, which is why the above piece became a prototype to test bend take-ups only. I also came up with a new design for the side reliefs.

 
Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
Hard DriveHard DriveOptical DriveOS
OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
AudioAudio
Dayton Audio DTA-100a Asus Xonar STX 
  hide details  
Reply
 
Project Al
(69 photos)
 
CPUMotherboardGraphicsRAM
Intel 2700k Gigabyte UD4 MSI 580GTX Lightning Xtreme Edition 3GB 2x4GB G.Skill @ 1600mhz CL6 
Hard DriveHard DriveOptical DriveOS
OCZ Vertex II SSD OCZ Vertex II SSD LG Blu-Ray/HD-DVD Combo Drive Win 7 Ult 
MonitorMonitorKeyboardPower
Achieva Shimian Acer G235H XArmor U9BL Corsair HX1000W 
CaseMouseMouse PadAudio
Fractal Define R3 Silver Arrow Razer Naga Ultimate Razer Goliathus Speed Edition Polk Audio RTi-A1 
AudioAudio
Dayton Audio DTA-100a Asus Xonar STX 
  hide details  
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