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Scratch Build - Aluminium Extrusion / 3D Printed DIY case

post #1 of 9
Thread Starter 
So, after deciding that I didn't like my 800D all that much anymore... and not really liking any of the cases on the market at the moment (or they were too expensive) I have decided to make my own.

My requirements for the case
1. Fit at least 2 360 rads (The design actually allows for 2 360s and 2 480s)
2. Fit a large tube reserviour
3. Fit my Aquero 6
4. Be easy to work on and change / remove parts
5. Look cool

Here are some final shots my 800d build before it's disassembly.





The 800D was nice but had it's issues, mainly that i couldn't close the side panel or the fans got too loud, and after removing the lower drive bays to fit the 240 rad the case had become structurally unstable and would easily bend and twist.


Here are my early (crude but dimensionally accurate) drawings of the case. Some of the stuff later changed but overall it's pretty similar. The drawing shows the Lian Li Motherboard tray, PSU mounting, Rad mounting, Aquero, power / reset buttons and the 270 photon tube res.





After mocking up the case, i ordered my black anodized aluminum extrusions and started to print my brackets for assembling the case.

All the extrusions used for assembly:



Assembling the main base



Most of the main frame assembled:



Lian Li mobo tray & temporary PSU mounted. Mobo tray is held in with 4 3D printed clips for easy removal. Also shot of test fitting the meshy front & one of the rads







Various assembly photos: (I later took it apart again partially to install GTX1080 & Block)







Here it is somewhat assembled and running, still tons of work to do





More to come...
    
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post #2 of 9
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post #3 of 9
Thread Starter 
Mixing up my pastel color and test fitting some LEDs in the new waterblock...
Dunno if i'll do the LEDs in blue or white.





    
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post #4 of 9
+1 for using aluminum slotted extrusions. thumb.gif
post #5 of 9
Thread Starter 
Quote:
Originally Posted by Spotswood View Post

+1 for using aluminum slotted extrusions. thumb.gif

Aluminum 2020 extrusions are awesome, it makes it so easy to build and expand stuff.
    
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post #6 of 9
Where did you order your aluminum from? I'm thinking of going this route for a case that I want to build, and I'm having a hard time finding a good supplier.

EDIT: Awesome case BTW! I especially like how you mounted the Aqueros and power buttons.
Edited by Drain-O - 7/22/16 at 11:25am
post #7 of 9
Thread Starter 
Quote:
Originally Posted by Drain-O View Post

Where did you order your aluminum from? I'm thinking of going this route for a case that I want to build, and I'm having a hard time finding a good supplier.

EDIT: Awesome case BTW! I especially like how you mounted the Aqueros and power buttons.


Thanks, I got them from Misumi. Best price i've seen and they do the cuts to whatever size you want.



Also, I've just got my hands on a CNC machine so now i can make some more custom goodies for this smile.gif
    
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post #8 of 9
Thread Starter 
Latest update... i CNCed a new front panel and painted it gloss black. It matches the case really well now, nice and solid too.

Next, i'll be redoing ALL the brackets and mounts with CNCed aluminium.







I also need to make a diffuser for that upper LED strip, cause clearly right now that looks like crap.
    
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post #9 of 9
I like it. I considered extrusions when making my build ( http://www.overclock.net/t/1605094/my-take-on-the-ultimate-scratch-build-lan-case-the-butler-p-47 ) but went with square aluminum tubing and friction fittings instead. In consequence, I lost a great deal of modularity (design trade-offs, right? smile.gif ).

Love to see these scratch builds.
BUTLER P-47
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BUTLER P-47
(16 items)
 
  
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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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