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Anyone interested in a *slightly* different SFF scratch build?

post #1 of 4
Thread Starter 
Would anyone be interested in seeing a build log for a solid casted aluminum SFF case? I recently setup a mini forge in my backyard in the old fire pit and melted down 10 lbs of aluminum that I had laying around doing nothing into 1/2 lb ingots to use for projects. Im playing with it now and it looks like I can cast metal as small as 5mm in thickness which could then be sanded down.

I was looking at my Hadron build (The Acorn) since its nearing completion and realized its pretty impractical to use long term because of the compromises I made in getting everything to fit. I have 2 options at this point, Buy another Hadron case and make a case.

I've never seen a scratch-built solid casted case before, and 10lbs of aluminum should be able to make a decent custom SFF case out of. Im going to be using the Lost Foam method where you sculpt pieces of Styrofoam together and place it in sand as a mold. The melted aluminum then gets poured on top of the foam and pretty much vaporizes letting the aluminum take its place.

The cool thing about this is that I dont have to make a plain box and can be as detailed as I want with any kind of ornamental and aesthetic details.

If theres any interest let me know, ill be finishing the hadron build up early next month and then debating on my two options for the build lol. If theres interest I will document the process on video every other day (shouldnt take more than a week or two since I have all the components)
Edited by ChainedHope - 2/16/16 at 10:16pm
post #2 of 4
Yes, I would like to see a cast case.

How accurate would it be? Could you, for example, put the motherboard stand-offs directly into the mould?
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Lori Lemaris 023
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Felicity Harmon
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post #3 of 4
Thread Starter 
Quote:
Originally Posted by WiSK View Post

Yes, I would like to see a cast case.

How accurate would it be? Could you, for example, put the motherboard stand-offs directly into the mould?

I could put the standoff holes into the mold, but not mold the standoffs into it itself. I could with another casting method but not with lost foam. Well unless i made the stand offs out of foam and casted my own lmao, then I could totally do it.
post #4 of 4
Thread Starter 
If anyone is interested in the process Grant Thompson "The King of Random" did a few short videos on making a mini forge/foundry as well as the Lost Foam casting technique and a Styrofoam cutter. I used all of his designs for my little working area with the mini forge being up-scaled by 1.5x.

Grants Channel:
The King of Random

Videos of topic:
How To Make The Mini Metal Foundry
Melting Cans With The Mini Metal Foundry
How To Make The "Stryo-Slicer"
How To Turn Styrofoam, Into Solid Aluminum
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