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[Project] Pearl in the Rough - Page 6

post #51 of 326
Thread Starter 
Yeah I've considered making some type of mold. The good thing is that with the case gutted like it is ATM it is pretty much just a shell. Nothing would get in the way of clamping and that would save me from having to make an inner mold. I also just got a good deal on a 4-pack of Irwin quick clamps to add to my growing collection. I think with a little patience and maybe an extra hand or two to help I can get a better bend. With some help I can keep the acrylic hot while some one else clamps as many places as possible. I will also see what I can do to make an outer mold. The inner radius of the bend needs to be 3/4" and the outer needs to be 7/8".
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post #52 of 326
i have done some plastic bending on a slightly smaller scale like this and doing that method worked. i made a huge MDF block (2' x 2' x 0.5') and then cut it to the shape i wanted, cutting out the thickness of the material too. then i stuck the plastic in an oven for a while and then took it out and compressed it in the mould. worked real good.
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post #53 of 326
Thread Starter 
Alright, got some work done. Got my square aluminum tubing in.



Used some to mount the HDD rack.





I'm using flat head hex screws and press in nuts wherever I can, to hell with rivets.

Making up some new trim/support bars.







Screwed the bottom of the trim piece to the HDD rack mounting bracket.



Top gets screwed to the frame.





Same deal for the second piece.





The bottom will be secured with a bracket like this.







That bottom mount is just a prototype. I'll make more sturdy one next. These uprights will also support the 5.25" bay sides. That's next up after I redo the bottom bracket.

Oh and Delvies might be able to get me a piece of acrylic in the size I need. The problem is is that there is a 50% chance of a corner getting broken off by UPS in transit. They can't make any guarantee. I'll wait and see what the other company I emailed says.
Edited by shinji2k - 7/22/09 at 3:44pm
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post #54 of 326
hey glad things are looking up! i love those hex screws you are using. might use them on my project! what is the exact name for them?
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post #55 of 326
Thread Starter 
Quote:
Originally Posted by oliverw92 View Post
hey glad things are looking up! i love those hex screws you are using. might use them on my project! what is the exact name for them?
Product info: http://www.mcmaster.com/#91253a147/=2v0fdw
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post #56 of 326
thanks man. those will look pro on my mini-me project
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post #57 of 326
Thread Starter 
I switched out the old bottom brackets for a couple of these.



Next is the 5.25" bay.





The mesh gets secured to one side with a bracket I made.







It's notched so when I tighten down the screws it clamps the mesh in. This makes for easy removal. Once I put the acrylic/aluminum shell on this will be the easiest access to the 5.25" drive bay so it being easily removable was important.

Sides get screwed to the uprights.







To actually install the DVD drive and fan controller, they will be screwed to a cage that will slide into that opening. I'm still mulling over the design and trying out a couple things. Hopefully I'll have more on that tomorrow.

I've also been testing out my fan controller. The Lamptron FC-2 is a PWM based controller. Instead of the tradition design it uses a rheostat to drive a circuit that controls a transistor. The duty cycle of the transistor (how long it is on/off) determines the output voltage. So if the PSU is supplying the fan controller 12V, to have your fans running at 6V requires a duty cycle of 50%. This is a much more efficient way of controlling a fan, that is why the Lamptron can handle 45W a channel. The problem with this is most fans aren't designed for PWM controllers. Basically the power comes in bursts and many fan motors will make an annoying electrical noise at an audible frequency (this controller tends to stay in the 300Hz-1kHz range). To get around this I plan on installing capacitors in parallel to try to smooth everything out a bit. I'm been using some salvaged caps of varying capacitance and a couple fan extenders to figure out exactly which caps I need to order.







I plan on soldering the caps in where there are empty spaces meant for diodes. The annoying thing is that each fan needs a different size cap. One fan usually needs somewhere between 47uF and 100uF. Two fans on the same channel need 330-470uF and my three 14cm YL medium speed fans need a 2200uF cap for their channel. So I've ordered an assortment of 16V UCC caps to put in there.
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post #58 of 326
man.. i sooooooooooo would not have wanted to be up against you in the polls.

hell.. i would've sent my vote to you.
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post #59 of 326
Thread Starter 
I don't know, BrassIe looks good. Even if I had gotten this to where I like it there would have still been some good competition.

I don't like being rushed by a deadline anyways . I need time for my genius to shine .
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post #60 of 326
oh and its shining man! i'm loving what you're doing. it looks so damn good. i like that new 5.25" bay you made.
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