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My take on the ultimate (scratch build) lan case: the BUTLER P-47

post #1 of 63
Thread Starter 
I'm starting my first custom (non-standard component) build; going a bit ambitious for my skill level (scratch build!) so always glad to hear your opinions. Here are my criteria (not in order of importance):

1. Integrated speakers
2. Integrated line power, including surge protector.
3. Integated monitor.
4. Amazing air flow, positive pressure--intake in bottom and clear flow path to top heat exhaust.
5. All front-panel connectivity.
6. Retro (think WWII) flight panel control and readouts (analog gauges, toggles, and etc.)
7. Aluminum build from scratch.
8. Moderate budget (this explains some of my component choices).
9. Water cooled CPU, air cooled GPU (for now).
Edited by Ergosum - 7/15/16 at 9:57pm
BUTLER P-47
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BUTLER P-47
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post #2 of 63
Thread Starter 
Conceptual Layout:

Basic layout (Solidworks cad). Note that the side, back, and monitor mount panels are not shown, neither are the Amazon basic speakers on either side of the control panel. Airflow is in through the bottom, through the radiator, and out through the top. Gauges on front panel are (left to right) intake fan 0-15 VDC, exhaust fan 0-15 VDC, 0-0.25 inH2O (inside case vs. atmospheric). I plan on having greater than the standard fan area worth of grill/filter in the bottom air chamber to minimize intake restriction.

Also note that I'm doing away with the standard rear panel IO! I'm moving all the necessary IO to direct connect and panel mount extensions. There will be a 1" gap between the motherboard mount panel and the case wall that mounts the monitor to route cables through.

Toggles are (by column): Column 1: Line power on/off (will have red toggle cover), Column 2: Momentary system power, momentary reset, constant led on/off. Column 3: Intake fan on/off, intake fan 3 position speed. Column 4: Exhaust fan on/off, exhaust fan 3 position speed.





Note: For sizing (I'll be using different hardware but the sizes should be very close), I used models from Grabcad: an Asus Gene (Author: Yang Ji), a model of a ASUS GTX 980 Matrix (wanted to size for a very large card) (Author: Yang Ji), and a ATX power supply model (Author: Pedro Navarro).

I've got some of the basic frame and the front panel nearly done. Pictures to follow. I'm also starting this log over on modders-inc.
Edited by Ergosum - 7/15/16 at 7:47pm
BUTLER P-47
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BUTLER P-47
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Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
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Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
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XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
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post #3 of 63
Thread Starter 
Design decisions:

1. Rivet instead of welding/brazing
2. Motherboard tray and front instrument panel = painted black, remainder = polished aluminum.
3. One 240 radiator (on intake), two 120 mm intake fans, two 120 mm exhaust fans. The fans will be connected to 3 way toggle giving high, medium, and low speeds.

FRAME AND CASE MATERIALS:

-Aluminum sheet, 0.060" (Local metal supply store)
-Aluminum tubing (0.050") from EZTUBE (sized for friction fittings), 1"x1" square
-Friction fittings for the tubing (EZTUBE), elbows, tees, four-ways, and etc.
-Riveting tool and 1/8 grip x 1/8 diameter pop rivets. (Stanley, from HD)
-Self-etch primer (Rust-Oleum, from HD)
-Flat black enamel paint (Rust-Oleum, HD)
-Wet/Dry sandpaper in 400, 800, 1200, 2000 grit (3M, HD). I have some rougher grit (dry only) on hand already at home. I've read that you don't want to go below 80 on aluminum.







WATER COOLING COMPONENTS:



ELECTRICAL COMPONENTS AND GAUGES(SO FAR):







ELECTRONICS (SO FAR, MONITOR, HD, GRAPHICS CARD (STRIX 1070!) ON THE WAY:



Bending, cutting and painting of the front panel on the way.

-
BUTLER P-47
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Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
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Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
CoolingCoolingOSMonitor
XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
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BUTLER P-47
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CPUMotherboardGraphicsRAM
Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
Hard DriveCoolingCoolingCooling
Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
CoolingCoolingOSMonitor
XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
PowerCaseMouseAudio
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post #4 of 63
Definitely ambitious and I'm definitely subbed!
post #5 of 63
Thread Starter 
Front panel, Part 1:

Cut out material from 0.060" aluminum sheet:



Prep bending brake ($36 harbor freight special...but hey, it worked) and bend material. Panel is ~33º from vertical. Scribe for instruments and toggles.







BUTLER P-47
(16 items)
 
  
CPUMotherboardGraphicsRAM
Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
Hard DriveCoolingCoolingCooling
Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
CoolingCoolingOSMonitor
XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
PowerCaseMouseAudio
Corsair CX Series, CX600M, 600 Watt (600W), Sem... Scratch Build! See my worklog (BUTLER P-47) Logitech g500s AmazonBasics AC Powered Computer Speakers (A150) 
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BUTLER P-47
(16 items)
 
  
CPUMotherboardGraphicsRAM
Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
Hard DriveCoolingCoolingCooling
Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
CoolingCoolingOSMonitor
XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
PowerCaseMouseAudio
Corsair CX Series, CX600M, 600 Watt (600W), Sem... Scratch Build! See my worklog (BUTLER P-47) Logitech g500s AmazonBasics AC Powered Computer Speakers (A150) 
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post #6 of 63
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Samsung 850 EVO 4TB SSDs Samsung 950 Pro 512GB m.2 SSD boot drive Noctua NH-D15S Cpu cooler Win 7 Ultimate 
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Corsair AX760 Scratch built. Currently under construction at ... Logitech M525 El Cheapo Allsop hard plastic 
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post #7 of 63
Thread Starter 
MOTHERBOARD TRAY, BEGINNING FRAME, AND PAINT











Sand (400 grit)

Primed with self-etching primer (3 thin coats):




Color coat (flat black enamel, 2 thin coats), wet sand (400 grit) color coat (2 thin coats):



Another wet sand for the front panel (400 grit again) and a final 2 color coats. I like the uniform textured flat black enamel, so I'm leaving it this stage (not fine sanding or polishing):

BUTLER P-47
(16 items)
 
  
CPUMotherboardGraphicsRAM
Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
Hard DriveCoolingCoolingCooling
Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
CoolingCoolingOSMonitor
XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
PowerCaseMouseAudio
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BUTLER P-47
(16 items)
 
  
CPUMotherboardGraphicsRAM
Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
Hard DriveCoolingCoolingCooling
Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
CoolingCoolingOSMonitor
XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
PowerCaseMouseAudio
Corsair CX Series, CX600M, 600 Watt (600W), Sem... Scratch Build! See my worklog (BUTLER P-47) Logitech g500s AmazonBasics AC Powered Computer Speakers (A150) 
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post #8 of 63
Thread Starter 
Note the pop rivets on the motherboard tray (previous post)--they are working out very well thus far. For the front panel, I'm going to leave the rivets bare aluminum for contrast against the black of the panel.
BUTLER P-47
(16 items)
 
  
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Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
Hard DriveCoolingCoolingCooling
Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
CoolingCoolingOSMonitor
XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
PowerCaseMouseAudio
Corsair CX Series, CX600M, 600 Watt (600W), Sem... Scratch Build! See my worklog (BUTLER P-47) Logitech g500s AmazonBasics AC Powered Computer Speakers (A150) 
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BUTLER P-47
(16 items)
 
  
CPUMotherboardGraphicsRAM
Intel Skylake 6600K ASRock Z170M Extreme4 ASUS GeForce GTX 1070 STRIX Corsair Vengeance LPX 16GB (2x8GB) DDR4 DRAM 32... 
Hard DriveCoolingCoolingCooling
Samsung 850 EVO  Aquacomputer Aqualis D5 100 ml, G1/4 Magicool 240 G2 Slim Radiator Phobya CPU-Cooler UC-1 Extreme Intel 775,115X,1... 
CoolingCoolingOSMonitor
XSPC FLX Clear 7/16" ID 5/8" OD (15.9 / 11.1mm)... 4 x Cooler Master JetFlo 120 Windows 10 Home (x64) Acer GN246HL Bbid 24-Inch 3D Gaming Display (14... 
PowerCaseMouseAudio
Corsair CX Series, CX600M, 600 Watt (600W), Sem... Scratch Build! See my worklog (BUTLER P-47) Logitech g500s AmazonBasics AC Powered Computer Speakers (A150) 
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post #9 of 63
Looks awesome. Like what I see
post #10 of 63
Very cool idea, keen to see the rest of the build
Ol'Faithful
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Ol'Faithful
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