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[Build Log] - Tesla 175, Caselabs TH10 build

post #1 of 26
Thread Starter 
Project Overview
I have named this project the "Tesla 175" as I am a big fan of the scientist Nikola Tesla. The number 175 is an arbitrary number I chose to distinguish this log from others which have likely also used Tesla in their title. This rig will be used mainly for gaming, although it will see general use and occasionally run numerical simulations. I started acquiring parts for this build about a year ago, and have taken my time both because I was busy taking classes last year, and for financial reasons. So far, I have purchased most of the cooling infrastructure and the power supply. All of the hardware will be purchased some time in the next month. For now, I have a lot of work to do assembling the system as much as I can without the actual blocks to connect to. The goal for this build is a powerful and quiet rig. I have assembled a few water cooled rigs before and have been disappointed with the noise levels. In addition, I just want to create something that I think looks nice. Not all of my choices are motivated by top performance, some things that I will do with this will be just because I like the way it looks.

Hardware
This is list is still dynamic,as I actually have not purchased most of this and I will still be making decisions as I go along

Case: Caselabs TH10
CPU: Intel 4930K
Board: Asus RIVE or EVGA Dark
RAM: Corsair Dominator 1866 MHz 32GB
GPU: EVGA GTX 770 x2
HD: Samsung 840 pro 2x 256 GB in raid 0, 1TB Seagate Spinning Disk
Power Supply: Corsair AX1200i

Cooling
4x Alphacool UT60 480mm rads
39x Noiseblocker NB-BlackSilentPro PL-2
2x Swiftech MCP35x2 with heatsink and 80mm fan
2x AQ Aqualis Pro 880ml
2x AQ flowsensor
2x AQ filter
Block for CPU, GPU, Board, and RAM (undecided)

Misc
The cooling will be dual loops with monitoring and control by AQ Aquaero 5. I will have to look into other build logs who have attempted this, but I would like one Aquaero 5 for each loop. In addition, I have designed and machined some custom parts to hold some of the cooling which will be shone later.
Edited by mphysgr - 9/20/13 at 6:17am
post #2 of 26
I did three loops with two A5's in my last build and I am doing dual loops with two A5's in my current build in a TH 10. The 880 Aqualis will be a good choice to help fill up space. You will find that your MB will look quite small in the TH 10. Also, be aware that the Aqua filters are very restrictive and can be difficult to integrate in your loops.
Cheers
Edited by theseekeroffun - 9/2/13 at 11:05am
DUALBRAIN
(15 items)
 
  
CPUCPUMotherboardGraphics
Xeon X5680 Xeon X5680 eVGA SR-2 eVGA GTX 780 Ti 
GraphicsRAMHard DriveCooling
eVGA GTX 780 Ti 24 GB Corsair Dominator Samsung 840 Pro Aqua Kryos x 2 CPU, Aqua Nickel Ti x 2, MIPS MB... 
OSMonitorKeyboardPower
Win 7 Ultimate Dell U3415W Func KB 460 & Happy Hacker Pro 2 Corsair 1200 AXi 
CaseMouseAudio
Case Labs TH 10 Func Audio Engine A5+ 
  hide details  
Reply
DUALBRAIN
(15 items)
 
  
CPUCPUMotherboardGraphics
Xeon X5680 Xeon X5680 eVGA SR-2 eVGA GTX 780 Ti 
GraphicsRAMHard DriveCooling
eVGA GTX 780 Ti 24 GB Corsair Dominator Samsung 840 Pro Aqua Kryos x 2 CPU, Aqua Nickel Ti x 2, MIPS MB... 
OSMonitorKeyboardPower
Win 7 Ultimate Dell U3415W Func KB 460 & Happy Hacker Pro 2 Corsair 1200 AXi 
CaseMouseAudio
Case Labs TH 10 Func Audio Engine A5+ 
  hide details  
Reply
post #3 of 26
Thread Starter 
Current Progress
As of this point in time, I have done some minor modifications to the 39 NB PL-2 fans. This is the stock photo.



I removed the factory sticker and replaced with black vinyl stickers (I got this idea from cpachris and BBBB). I also sleeved the cable in MDPC black. To get the sleeved cable to fit in the fans plastic channel, I had to dremel the fan housing a little bit. I also used another little piece of vinyl strip to hold the cable in the channel. This what they look like now.



I have installed 2 of the four radiators into the case at this point.





Sorry for the amateur photography. I might learn to take better photos as I go along but it is not something I want to invest a lot of time in.
post #4 of 26
Thread Starter 
Quote:
Originally Posted by theseekeroffun View Post

I did three loops with two A5's in my last build and I am doing dual loops with two A5's in my current build in a TH 10. The 880 Aqualis will be a good choice to help fill up space. You will find that your MB will look quite small in the TH 10. Also, be aware that the Aqua filters are very restrictive and can be difficult to integrate in your loops.
Cheers

Thanks for letting me know. I was not sure if there might be some issues in the software with two AQ 5's. I am glad that you able to get them working and I will check out your log to see how you are implementing them.

Your are absolutely right about those filters. They caused me a few headaches to figure out how to integrate them into the loop. I am pretty sure I have a solution that will work but we will see when I actually start assembling them.
post #5 of 26
Thread Starter 
Custom Parts
In order to put all of the cooling components where I wanted them, I designed and machined some parts to hold everything. I started with a crude drawing in Autodesk inventor. I did not approach the detail that some members have used in CAD designs. I just waned to get some idea of how things would fit together. The photos are not terribly descriptive, but I will be clear about each parts function when I assemble everything (hopefully soon).





I have access to a full machine shop at my workplace, so I started with some aluminum plate and bar stock, my cad drawings, and machined the necessary pieces.



These are with Jim at Caselabs right now, who was willing to powdercoat them black to match my TH10. Hopefully, they will be done soon and on their way home for me to start putting things together. Thanks to Jim and all of the staff at Caselabs for their incredible dedication to their customers.
post #6 of 26
Thread Starter 
While I was thinking about it, I thought I would mention an issue I had with using two of the Caselabs accessories simultaneously. On the Power supply side of the TH10, I am using the CL HDD fan mounts. I also wanted to use the horizontal accessory rail in conjunction with some of my custom pieces. What I noticed is that the accessory rail does not fit if you are also using the fan mounts, the part of the rail with the attachment holes bumps into fan mount casing and you cannot fit it in to fasten the screws. To solve this, I just machined a little bit of the accessory rail away until it fit. No big deal. Did anyone else have this issue? Maybe I just did something stupid? My solution with the machined accessory rail is shown in the picture below.

post #7 of 26
Thread Starter 
Update
With the release of the new Caselabs S5, Jim and company are pretty busy filling those orders. The timeline seems to be about another 3-5 days to get my custom parts painted, and another 4-5 days for shipping. So while I am waiting on those parts, I started working on assembling some of the fittings, pumps, res's etc. The cooling setup will be a dual loop, one for CPU, board, RAM, and one for the GPUs. Each loop will have an Aqualis 880ml Res, Swiftech mcp35x2, AQ flowmeter, AQ filter, 2 alphacool UT60 480mm with fans in push/pull, and a drain valve and fill port.

I installed the LED's into the aqualis. I doubt it is necessary, but I decided to use rubber cement to help hold the wires in place. Rubber cement is not strong, but it is easily removable. I do not think I need a strong adhesive, as once you have the leds installed and the metal plate screwed down, they don't really move, but I decided to do it anyway to help with the wire management. The hardest thing is keeping them out of the way to get the cover plate installed. I plan on sleeving the LED tails in the future.



I also decided to use the heatsinks on the MCP35x2's. I am not sure how much of a difference they truly make, but at least there is the possibility that they improve pump operation, increasing lifespan and reducing noise. I wanted to use 25mm thick 80mm fans with these sinks. Normally, you are limited to 15mm thick fans, but I could not find any I liked. The problem with the thicker fans is that the black mounting posts are shorter than the fan base. To solve this problem, I just bought thicker rubber bumpers similar to the ones the pump ships with, so that I can still mount them without the fan touching the plate they will be mounted to.



I also just spent some time putting some of the fittings together, changing their O-rings, and switching the silver screws for black on the AQ filters.



Hopefully, I will get my parts back soon, and I will be able to show you the assembly of the cooling infrastructure.
post #8 of 26
Thread Starter 
Update

I have received the parts back from getting powder coated. It will take me a while to get everything assembled as I do not have large chunks of time at the moment, so one thing at a time. Rather than showing all the parts again painted, I will show them in groups as I explain their purpose and demonstrate how they will be used in the TH10. I did my best to optimize the design, but the issue is that some screws will end up hidden as I assemble everything, meaning that there is a very specific order in which I have to do things.

First, these parts are for a radiator support.


One of my goals was to get 4x 480mm rads in the TH10 without using a pedestal. I also wanted to keep as many of them on the PS side so that I had room to show show off the pumps, res's, etc on the MB side. In addition, by separating the rads from the hardware, I should keep ambient temp down on the MB side of the case. Therefore, I decided to put one of the rads on the top of the MB side, one on the top of the PS side, one on the bottom of the PS side, and a third one somewhere on the PS side as well. Figuring out how to get the third one over on the PS side took some thought. CL makes an accessory to mount a radiator on the PS side, but this accessory turns the radiator on its side to use the vents on the PS door. THe problem with this, is that it does not leave much room for airflow for that radiator, as the MB tray is very close to the exhaust side of the rad, and it is a blockage to the air moving up from the bottom radiator and the air coming in to the top radiator. So I decided I wanted to find a way to essential stack the radiators, so that all of the fans blow in the same direction, and the airflow and the natural motion of the heat all moves from the bottom of the case to the top of the case, the parts above were my solution. In order to mount them, I drilled 3 holes in the TH10.



I am using these special screws with a nylon patch as some of them will become inaccessible and I do not want them to come loose.


Once they are mounted in the case, they look like this:


The three flat pieces will attach to the radiator, I will not install these yet because of the specific order I mentioned. But, just to give you an idea, here is how the radiator will sit on these parts.

I will try to get some more stuff assembled and show the results tomorrow.
post #9 of 26
Thread Starter 
Update
More custom parts

I did not get as much done as I wanted, but I will show the progress I did make. The next part I made is a back-plate to hold the reservoirs. I have seen others install two reservoirs directly to the metal plate separating the MB and PS side in the TH10, but I decided I did not like this because it felt too cramped, I could not put the Res exactly where I wanted them, and I do not really like the gap between the MB tray and the rest of the mid plate. Therefore, with this custom back plate shown below, I can cover that gap, and install the Res exactly where I want them.

I already installed a Led strip on the back of the panel, which should work as a back light as the Leds will be hidden. This will become more clear after I install the panel.
I also machined some extra parts I will install onto this plate which will be used for some future additions I have not quite settled on yet.

Here they are installed on the panel.

And finally, the main purpose of the panel, to hold the Reservoirs. Here they are roughly installed, I have to mess with them a little to get them straight. I will finalize their positions and do some initial connections to the the Res before installing the plate into the case.
post #10 of 26
subbed! i love TH10 builds
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