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Project: Deskasaurus

post #1 of 35
Thread Starter 
I was playing Battlefield one night and went to gram my joystick which was a USB one. The wires down behind the desk were tangled and as I pulled harder, it pulled the power out of my PC. Bugger!!! Can't someone think of a better way? I know there is wireless for the devices but what about all the damn power cables, video leads, sound leads, multi boards and dust? It was a that point I decided, "Right! Had enough. I'm going to build a desk and hide it all.

Later that night, I sat down with a pen and paper and started drawing. At the top of the paper I wrote in big letters, "1 cable in and 1 out!!" and under this I wrote, "the desk is the computer" and "It must look as good at the back as in the front".
And so with only these 3 things in mind and a rough sketch, I went down to the hardware store and bought the timber I though I would need to make the desk. When I got down there, the price for the good wood was astronomical. So foolishly I went for the cheap stuff. Which was boxing grade. Yes I know tsk tsk!

The list went like this. (And bear in mind, this is only the very first trip to the hardware store)

2 sheets of 2400 x 1200 x 20mm ply @ $130 (for the desktop and console)
2 sheets of 2400 x 1200 x 12mm ply @ $70 (For the bottom and top of the desk frame and it was on sale)
3 sheets of 2400 x 1200 x 4mm ply @ $45 (To skin it with)
2 sheets of 2m x 600 x 6mm hardboard @ $15 (It was on sale and I thought I might use it)
1 sheet of 2400 x 1200 x 20mm custom wood @ $40 (possibly for the doors and shelves but at that stage I wasn't sure)
8m of 75 x 50mm framing cut to 1m lengths @ $30
8m of 75 x 20 pine decking @ $20 (to use as framing also in an attempt to cut down on weight.)
4m of pine corner edging @ $20
4m of 20mm quarter round @ $12
4m of 50 x 20mm @$15
1 sheet of 900 x 600 x 4mm perspex @ $60
1 litre kit of Polyester resin and fibreglass mat @ $26
1 tin of automotive filler @ $15
3 tubes of "no more nails type adhesive" @ $21 (To glue the skin on)
1 box of 60mm self drilling wood screws @ $30 (About 300 screws to a box)
1 box of 20mm self drilling screws @ $21
1 bag of panel pins $3
A new Ryobi Orbital Sander @ $70 (MY old one was on its last legs and I never need an excuse to buy a new tool)
A new Ryobi belt sander @ $75 (Same excuse as above)
A new Ryobi router @ $90 (Didn't have one and knew I would need it)
A stand for my drop saw @ $60 and as it was on special and while I was spending up large and while I had the trailer blah blah blah
A set of Hole saws up to 127mm @ $25
A set of wood drills @ $12
Some cupboard hinges and door stop pistons @ $15
2 rolls of sand paper @ $30
2 saw stools @ $60 (How rude!! $60 for some saw stools?)
2 rolls of masking tape @ $4
3 extra sanding belts for the new belt sander @ $18
A new multi 6 port multi box with circuit breaker and surge protection @ $29 (This was forward thinking for when I wired it)
A standard 240v dual plug wall socket @ $15

Grand total so far of $1076. At this point I was thinking, crap!!! The wife is definately going to kill me.

Weekend 1. The main desk frame.
Basically, I cut the shape out of the 2 12mm sheets of ply and framed to the shape. I made the shape for the bottom of the desk 50mm shorter all round so the desk top would over hang somewhat. (We'll talk about my measuring later)


Weekend 2: Do the shelves and doors for the cupboards
Using the off cuts of 12mm ply, and some 2"x1" I made the shelves for the cupboards. the shelves sit on 2" x 1" bearers. I also put a back on the shelves so that nothing would fall into the back of the desk once finished. I also cut out the shapes for the cupboard doors but didn't do much after that.

Weekend 3: Skin the frame.
Unfortunately the photo's I took on my Iphone remain there........under the wheel of my car squashed forever.....and no I didn't save them to the cloud. The photo's I have posted were taken either on my Camera or from my new Samsung Galaxy.
Anyway, basically I cut the 4mm ply to a rough shape and by using small panel pins and sash cramps I glued the ply to frame.

Weekend 4: Desktop and finish the cupboard doors.
Thinking I knew the measurement of the desk so far, I cut the desktop to length and didn't measure the frame. Only to find out that my 50mm overhang was now going to be a 10mm over hang front and rear and 50mm on the sides. Hmmm bugger. 1st mistake but I can live with it.
By putting a sheet of 20mm ply ontop of the desk as it stood now, I traced the outline of the desk. Then I drew a larger paralell line to give my overhang. I then cut the radius on 2 sheets of the 20mm ply as the other sheets was the console and would need to have the exact same radius later down the track.
Next I routed the all the edges.
Onto the doors. While the router was out I did the edges on them as well and began hanging the doors only to find my frame wasn't quite square. Bugger. Mistake n umber 2. Why wasn't it square? Because my work shop floor had a buckle in it and I didn't set up a jig. Oh well!! too late now. I glued the damn skin on. So I hung the doors as best I could and put the finishing timber architraves around them.

Weekend 5: Sand and stain

Back down to the hardware store for some Stain

500mls of Mahogony Stain @ $21
.
At this point I was tossing up whether to prime and paint, or stain and laquer. I chose the later but in hinsight should have primed and painted.
So out comes the sander. I spent the whole weekend sanding to get a good finish on the framing ply. Then I stained it with a mahogany stain and used some black spray paint to darken it. While I was at it, I sprayed around the cupboards to get an idea of how it would look with the last of some black Laquer I had sitting around. Only about 500mls.


Weekend 6: Laquer and polish
At this point I went and bought primer, paint, clear coat and thinners.
4l Black laquer @ $80 (Not too bad considering what paint costs)
4l clear laquer @ $80
4l of Spray Putty @ $60
20l of 2 way thinners @ $65
4l of degreaser @ $35
A sleve of plastic mixing containers @ $20
Wet and dry sand paper 320, 400, 600 and 1000 @ $12

Grand total that week of $352


Not much to say here as it's self explainatory. See the photo's for the final result.




Weekend 7: Begin the console.
At this point it got a little more difficult. I had to make sure I was thin king 5 or 6 steps ahead and didn't make anything the wrong shape, too small or those types of things. I also had to decide if I was going to make an acrylic see through console and house the Mobo there, or if I would put it on one of the sides. I chose the later and glad I did. So began laying out the top console and getting a rough estimate of compartment size. I also decided to recess the sides and back in a grove. This would mean I would not have to create too much framing to nail plky to. In fact, in the end, I only fixed the ply back to the console on each end. With a recess top and bottom, it was secure and rigid.

The most difficult thing to do here was route in the grooves to take the back, and windows. I had to figure out a way of making the radius on both the desk top groove and the console exactly the same. So that when I eventually put in the perspex, speaker boxes and back, that it was all perpendicular.




Weekend 8 and Weekend 9: Speaker Pods and Centre Console
During week 7, I had ordered the speakers,and fan controller and had bought the stereo head unit, 12" sub and amp so I could complete work during week 8 and 9. I needed those components so I could make the console and get an idea of size and fit. Also, I ordered the water cooling bits and bobs over the entire course of the build. I'll put the price tag here as it is now becoming important.
Price tag

12" sub @ $65 new (Nice!! Only 300w but more than ample for a computer desk that was a great big resonating boom box)
Pioneer Car stereo @ $199 on sale
Sony Xplod Amp @ $150
Boss 6" x 9" 3 way speakers @ $85
Dub 5" 2 way speakers @ 45
Touch 2000 fan controller @ $85
650w PSU @ $90 (this will power the Amplifier and give me the ability to switch on and off without using heavier 240v wiring.)
XSPC GTX680 water block @ $150
XSPC CPU block, and EK Pump @ $150
XSPC 280 radiator @ $70
3m of Fluro green Tubing @ $60
Bitspower G14 pressure fittings and elbows @ $120
6 x Coolermaster Sickleflow 120mm Fans @ $130 (These things are the best bang for buck for airflow vs noise)
4 x UV reactive Sata cables @ $20
Black PSU cable extenders @ $60

Grand total of $1479

Let me just say that as I do not know too much about fibre glassing, I did not know that Polyester Resin will eat polystyrene where epoxy resin will not. Needless to say, now I know. Earlier in the week, I went and got a couple of blocks of Polystyrene. I made a couple of shapes out of polystyrene and killed the first shape with the polyester resin. So what you see in the photo's was actually a reject shape. However, it looks ok now I guess.




It's now Christmas and I'm on holiday. I have 3 weeks to finish this puppy before I start work again. So lets get Christmas out of the way and I can get into it and put in 10 hour days.

Week 10: The day after boxing day.
Time to honk up the compressor again and get this sucker painted. So I masked her up and spent the next 5 days trying to get a coat on it in between showers. The humidity didn't help either but I managed to do it.




Week 11 and 12: The fun begins.

I'll list the last items to be purchased now.
Switches to control Blacklight, Amp, Stereo and turn on the PC @ $40
Multi tool to cut holes @ $120
Blacklight and socket @ $30
Plasma Balls and Plasma tube @ $45 (These are yet to arrive)
Car Aerial @ $25
Sound activated Neons @ $45
1 extra lon Video cable @ $20
1 litre of Car Antifreeze for cooling liquid

Grand total of $325 for that week

List of things to complete:
  1. Make mounting brackets and mount Exhaust fans as well as Intake fans with radiator. Need to buy a tool to do this.
  2. Make false bottoms that match contour of the Window radius. My idea was to paint a black stripe on the inside of the perspex viewing windows. This would give the effect of hiding the gap of the false bottom.
  3. Define finally where the mobo will sit on the false bottom and lay out all the components so that holes can be cut in the false bottom for all the wires that need to come in to the motherboard.(This proved to take up alot of time thinking before I actually decided and acted.)
  4. Buy a couple of switches and buy the Neons. (I went to Super Cheap Auto for this and used automotive stuff as this is all 12v the same as the PSU in the computer. Therefor I can re-wire connectors and run it off Molex on the 12v PSU rails.
  5. Cut in the switches using the new Multi tool I bought.
  6. Test the stereo system out of the desk before wiring in case it isn't going to work.(Luckily it worked better than I had hoped. The sound on this thing will blow your mind!!!)
  7. Cut a hole and mount the Sub into the main desk body upstairs.
  8. I decided after making the centre console, that having 2 PSU's housed in there would cause heating issues and so chose to mount one of them in the body of the desk. I welded up some brakets and did this also.
  9. Screw down and Wire up amp, stereo and speakers and put that side of he desk to bed.
  10. Wire up the PC side, Led's, Neons and switches.
  11. plumb the water cooling
  12. purchase a black light and connect this up along with the 240v dual plug sockets. (I couldn't get anything in 12V so I have to wire it up off the 240v circuit I put in.)
  13. Cut holes for the USB 3 jacks as well as the Neon switches.
  14. Cut holes in the counter top to take 5" speakers and mount the car aerial. Also cut a hole big enought to let the video cables out of the enclosure and make some sort of nice surround for the hole.

Before I can wire this all up, I need to mount all the fans. Why? Because I want all the wiring to be hidden. Or as much as possible any way. And to do this, I have 1 of 2 choices. Cut holes in the desktop, mount the PSU's inside the desk body and feed wires up. This would mean that the desktop would be very hard to remove and would be tightly coupled to the desk bottom. Or the other option was to create a false bottom. This means that I could wire up independant of the bottom which was sitting upstairs already. I chose the later which turned out to be much harder than I bargained for. I didn't want to go into the hassle, time and expense of completely stripping a PSU back and re wiring it with longer braided wires.(Ironically I will do this retrospectively anyway but at my leisure).
So placement of the motherboard so that the wiring is long enough to reach was crucial. But there is another problem. I didn't count on making a false bottom when I worked out the height of the console and motherboard enclosure. When the water block for the video card arrived, I realised that I was playing with some very tight measurements. If my false bottom was too high, the top of the enclosure would sit on the video card water block. I could basically afford 27mm to give my video water block 5mm clearance. Now when you consider the board that will be the false bottom is 12mm thick, I basically have to make sure all the wiring will sit under 15mm. Now as we all know, most PSU's bundle their wiring with no real concern for order. So I had to split the wiring bundles apart on my Corsair 1000w modular PSU so the lay flat on the actual desktop. I then used masking tape and taped it all down. I also had to make sure that that I had room for routing Sata cables and Molex plugs.

But before any of that, I had to make the fans look pretty on the outside and also beable to mount them and the radiator. I used perspex to do this. And I also used one of my former projects. I made a CNC mill some time ago and used this to cut out the mounting holes and holes for the fans. This proved to be invaluable as I realised the an XSPC 280 radiator is designed for 140mm fans not 120mm like I ordered. So with some create CAD drawing I made my perspext mounting adapters and cut square holes in the side of the enclosure to take my new parts. I mutilated my old Tower case and took the metal fan covers out and used these to cover the holes from the fans to make it all look nice. I also butchered out some of the hard drive bays and used this as a bridge to mount the water cooling resevoir.

I will post some more photo's when the plasma balls arrive of the wiring in behind the console as well as a closeup of the radiator brackets. But for now lets see the final product. In the photo's you might see some scratches in the paint work. I have sinced touched them up. My sone dropped his corner when we were bringing it inside.

Final Specs:

Total Cost excluding the PC and Monitors = $3253
Total Cost including PC and Monitors = $7000


Desk
Height floor to monitor base = 1070mm
Height Floor to Desktop = 870mm
Length = 2000mm
Width = 1200

Sound System
Pioneer Car Stereo
Sony Xplod 350w Amp
12" Sub Woofer
2 x 6" x 9" Boss 3 way speakers
2 x 5" Dub 2 way speakers
650w PSU
240v input 12v output Transformer

Computer
Asus Sabertooth X79
Intel Core I7 3930k Hex Core @ 4.5GHZ
EVGA GTX 680
32GB Gskil Ripjaws 1866 XMP Ram
1 x OCZ Vertex 4 240GB SSD drive
2 x OCZ Agility 3 120GB SSD drives
XSPC Water Cooling CPU and Video
1000w Corsair Modular PSU
Asus 300m Dual Band Wireless A/N card



See the video I posted on Youtube here
http://www.youtube.com/watch?v=ybeZG3h7mKk

P.S. I'm getting a new chair biggrin.gif
Edited by Anzac - 1/21/13 at 2:22pm
post #2 of 35
Subbed

That is some serious work, I'm jealous of your desk thumb.gifeek.gif


PS: What is the song at the end of the vid?

The Chemical Brothers - Galvanize
Edited by KaRLiToS - 1/20/13 at 9:15am
Quad Damage
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Quad Damage
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post #3 of 35
Awesome! you got my vote for MOTM! wink.gifthumb.gif
   
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post #4 of 35
Thread Starter 
Thanks Dude!
post #5 of 35
This is absolutely amazing, outstanding work man. Good luck with MOTM, this makes my mod look like a kiddy toy. Welcome to OCN by the way!
    
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post #6 of 35
Thread Starter 
Thanks man.
post #7 of 35
Quote:
Originally Posted by Anzac View Post

Bitfenix G14 pressure fittings and elbows @ $120
I wasn't aware of this! Where?? tongue.gif
post #8 of 35
Thread Starter 
Eek. My Mistake. Bitspower fittings. I'll change it.
post #9 of 35
Quote:
Originally Posted by xbournex View Post

I wasn't aware of this! Where?? tongue.gif

Lol. BitFenix should start selling WC products now. Would love to see RADS and Fittings from you guys. biggrin.gif
   
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Hard DriveCoolingOSMonitor
Plextor M5S SSD Aqua-Computer Windows 7 Ultiamte Asus ROG Swift PG278Q 
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Asus VS247H-P CoolerMaster QuickFire Pro CoolerMaster V850 CoolerMaster Storm Troope(Modified) 
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Hard DriveCoolingOSMonitor
Plextor M5S SSD Aqua-Computer Windows 7 Ultiamte Asus ROG Swift PG278Q 
MonitorKeyboardPowerCase
Asus VS247H-P CoolerMaster QuickFire Pro CoolerMaster V850 CoolerMaster Storm Troope(Modified) 
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post #10 of 35
They should look like they were made to be in cases like prodigys
Awesome desk I would love to have one if it didn't give my mom a heart attack
 
Marylin
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Marylin
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phantom 410 modified rat 7 1 million dollor souround system sometimes when... 
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