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[Professional] Orb Fortress -by ne(V)esis-

post #1 of 74
2/8/10 at 7:53pm
Thread Starter 
Greetings community

Finally, after been a little busy with my duties during the last week, the weekend ended and I had time to start my modding.

Thus, formally beginning the introduction to my modding and I leave an information sheet. Followed by a descriptive journal of some of the processes, experiences and progress of manufacture thereof until its conclusion.
Which, I will be updating.

Good luck and greetings to all participants of that competition.

ne(V)esis

--------------------------------------------------------------------------

Description Sheet:
  • Project Name: Orb Fortress
  • Author: ne(V)esis
  • Manufacturing Materials: Aluminum & Acrylic
  • Diagram (updated):


Edited by ne(V)esis - 2/8/10 at 9:01pm
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post #2 of 74
2/8/10 at 8:33pm
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Friday February 5, 2010
  • First I will explain how I decided to make my mod:

    A few days ago, while I bought some cables and electrical equipment, I went through a store specialized in lighting, in which I saw hanging a lamp that inspired me to start my modding from it design.
    A few days passed when I went to see it physically and convince myself.
    Previously, I had some designs in mind to make from scratch, but It didn't like at all.
  • Yesterday, I bought the lamp and it wasn't until today, when I began to see its structure closely and to disarm it, to begin to adapt it to my mod.
  • Once disarmed and removed the socket for the bulb, I made the first diagrams of it. To facilitate the task of its design, making it better since my PC.
  • Here the first pictures of the process:


    Some pics from different angles


    Some pics from different angles


    Some pics from different angles


    Some pics from different angles


    Some pics from different angles


    Starting to dismantle the victim from the base


    Base removed and measured for 3D design


    Next structure removed and measured


    Intermediate structure removed and measured


    Now from above, removed and measured cone


    Socket support removed and measured


    Trying to remove the socket with some tools. But it was stuck or something...


    Better cut it!




    Now, using the sanding belt, we finish the tip!


    Socket removed!


    Once the lamp is measured, I proceed to arm again. Note that the cable from the socket is not longer

Edited by ne(V)esis - 2/8/10 at 9:00pm
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post #3 of 74
2/8/10 at 9:00pm
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Sunday February 7, 2010
  • Once measured all parts of the lamp, being designed in 3D.
  • Finally, I have the 3D design, and I start to add some details, such as stands to create the effect of a fortress, the power switch and a fan base.
  • I had some ideas to place the fan at the base, the original idea was of a blue LED fan, but not sure what size to choose: 120, 180 or 200mm. At the end, I opted for the 200mm blue LED fan.
  • Also, while designing, I liked the idea of putting acrylic between the stands and illuminating with blue LEDs.
  • Here the design diagrams:


    Isometric view


    Frontal view


    Wire structure isometric view


    Isometric view with the stands


    Frontal view with the stands


    Color - Isometric view with the stands. By the way, I love how the tribal stands and the three tubes looks!
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post #4 of 74
2/12/10 at 7:47pm
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Friday February 12, 2010
  • Again, the weekend begins and I have time to spend with my modding.
    On this occasion, I bought some items that I will use in my modding: as some LEDs of different sizes and colors (3 and 5mm, blue and UV), LED holders, an aluminium fan grill, resistors, and finally the 200mm fan with blue LEDs.
  • Here some pictures:


    Cooler Master 200mm fan with blue LEDs!




    The 5mm LED holders


    5mm UV LEDs


    3mm blue LEDs


    Resistors for each size of LEDs


    8" Aluminium fan grill


    The fan with the aluminium fan grill! It will look great!


    The fan without packing


    Case base with the fan


    OMG! Looks pretty good, without even being finished!
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post #5 of 74
5/12/10 at 7:32pm
Thread Starter 
Wednesday May 12, 2010
  • Since my last post until today, three months have passed. This is because I was so busy at work and I could not continue my project. An apology for that.
  • Recently, maybe a few weeks, I've got an excellent Mini-ITX motherboard for use in my project, which was donated by my brother in law! It is a motherboard with integrated processor: Intel ® Atom ™ 230 with a 533 MHz system bus, Intel ® 945GC and ICH7 and Intel ® Graphics Media Accelerator 950! (For more details visit the following link: http://www.intel.com/products/deskto...f-overview.htm)!
  • Also, last week I've exported to AutoCAD the stands of the chassis for laser-cut, and today I went to pick them up. It remains only the pieces of acrylic that will go between of each of the three stands. I think that I could make it or also choose the laser cut. I have these days for choosing!
  • Here some pictures of the progress:


    The drawing of the stands in AutoCAD 2008


    Here's the Mini-ITX Motherboard above the chassis. I need to make an aluminium support


    The laser machine cutting!


    Almost finishing!


    The chassis stands cut...!

Edited by ne(V)esis - 5/13/10 at 12:23pm
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post #6 of 74
5/16/10 at 5:52pm
Thread Starter 
Sunday May 16, 2010
  • This past Friday, I bought a piece of clear 6mm acrylic to start the pieces that I needed. Today Sunday, taking a break from work I decided to make such parts
  • Starting with the basic tool like a Dremel and reinforced cutting wheel, as well as the safety equipment: goggles and dust mask.
    Using a cutter, I traced the outline of the pieces of aluminium, using them as templates. Using a cutter, I traced the outline of the pieces of aluminium, using them as templates. Then, using the Dremel, I made a deep cut around the outline and finally with the cutting wheel I cut completely through the piece.
  • Then, due to the edges were rough, use a belt sander to remove the rough edges and leave as smooth as possible. This process was the most delayed of all, taking me like 2 hours ...
  • Finally, with the help of a polisher, I've polished all the edges that will be seen in the stands.
  • I left some extra acrilyc on all parts, which will include the blue LED and will be hidden inside the aluminum tube. However, that step will be a little later on when I start with the tubes...
    Last, I need to join the three pieces (like a Sandwich). Perhaps gluing them or using screws, depending on which idea is best.
  • I leave the pictures of the process:


    The piece of clear 6mm acrilyc


    With help of two Black&Decker "multi chambas" I made a improvised table to work


    Using a cutter to trace the outline and the aluminium pieces as a templates


    The outline drawing of the template


    It's time to wear the safety equipment!


    Once the outline is traced, I will use this baby to do the next step


    Deep trace done!


    Next, now using this baby to cut the piece






    Cut pieces, done!


    Now, using the belt sander to leave all the edges smooth!


    Smooth edges, done!


    It's time to cut those difficult corners


    Again, with help of the Moto-Tool...


    Time to polish the edges!




    Before...


    After!






    Stands completed (1st part)

Edited by ne(V)esis - 5/17/10 at 8:37am
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post #7 of 74
5/17/10 at 11:07pm
Thread Starter 
May 17, 2010
  • Due that I did not work today. I decided to go forward with my modding. It is time to make something with support for the motherboard.
  • Unfortunately, my brother used without prompting the piece of acrylic that I used for the stands. So I had to go buy a bit more (a piece of 17 x 17 cm) and making the trip, also a square acrylic rods of 1.2 cm side. It should be noted that as only going to buy that piece so small, I went to a place where I bought it to size of the motherboard.
  • That's when I started, tracing the fastening holes motherboard itself on the piece of acrylic. Then, to put the screws were two ways: by heating them and putting them under pressure in the acrylic or using a tap for threading them.
  • So I chose the second option, because the first, if something goes wrong, you can not be easily removed again, unless you break the acrylic.
  • So I looked for suitable drill for an M3 thread Tap. Use the bench drill for a more accurate hole and finally with a handle, thread the four holes.
  • Once done, it was time to square acrylic rod. Since the tips were opaque, I polish them and then one side pierced with a 1/8" drill for threaded to 4mm. And on the other side, had the idea to pierce with a 3mm drill, to place three LEDs.
  • Finally, I put the rods in place and put the motherboard based on it, using a special acrylic glue, I attached the base and the rods.
  • I think that was very focused and excited with the results,so I decided to buy a laptop SATA HDD of any capacity. So I went with a cousin, who had a 160GB and I sold it for $ 30 USD or $ 400 MX.
  • Tomorrow or when you have another chance, I will hold him inside the case, I'm still wondering what would be most appropriate place.
  • I leave the pictures of the process and progress:


    The piece of clear acrilyc


    Exact size!


    The three acrilyc square rods


    Starting to drill the base of the motherboard


    Full thread!


    Starting to polish the tips


    Before...


    After!


    Drilling the tips!


    Done!


    Now, threading one side




    This part of the process, was critical, 'cause I don't like how the motherboard fits into the tube, so I decide to remove him and use only the acrilyc support


    Measuring the motherboard base, trying to don't make a mistake


    Once I glue the base into the squared rods, I use a press to make sure it set perfectly


    Motherboard base done!






    Bottom view!


    The 160GB HDD


    Ideal size, taking into account the motherboard size and internal space!


    Extra pic! The tube that I did not used earlier, it was perfect for the 200mm FAN!
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post #8 of 74
6/6/10 at 9:59pm
Thread Starter 
Sunday June 6, 2010

  • After a few weeks of hard work, I had time to continue my project. On this day, I wanted to continue with the chassis stants. Sticking the two aluminium parts in the acrylic pieces.
  • I was very concerned to know how to stick them, but asking to several people, they gave me an excellent idea: to use double-sided tape! Here in Mexico, I only know of two types: first one is for wood (with a 1/8" thick) and the another one it's much thinner and transparent: bingo!
  • My luck was improving, 'cause that I had that tape in my house due I had bought it a long time, but did not work to me at that time. But now I took great advantage! So, I set to work!
  • The first thing was to give a correct finish to aluminium parts, since some were slightly scratched or bruised. So using a scratch fibber and a press, I armed myself with a lot of patience and scratch all pieces, one by one, following the same striped material!
  • Then, I cleaned up all the impurities of the acrylic pieces and started to put the double-sided tape all around.
  • Finally, very carefully, I attached aluminium parts making sure that both pieces are aligned. Since the tape stuck very well, despite how thin it was!
  • Here are some pictures of progress, greetings:


    A fast solution to scratch the aluminium


    Look at the different types of scratching! Nice, don't you?




    Scratched finished!




    The double-sided tape!


    Beginning to put the tape...


    OMG, at last!


    Carefully placing the aluminium pieces


    Work done!


    Extra pic!
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post #9 of 74
6/8/10 at 11:08pm
Thread Starter 
Tuesday June 8, 2010
  • Today, I had a chance to continue with my project. So I get to work!
  • I've proposed to place the first stage of the stands, holding them in the chassis, which still was not very strong, but tomorrow or when i got sufficient time, I will reinforce them with other extra screw or bolt. Avoiding the stands will also rotate.
  • I Believe that the chassis is taking more its shape, but I have to do with forced march since there isn't much time left ...
  • I leave some photos of progress:


    I used an aluminium sill


    Then, I draw a line of 2.5" from the tip and started to cut!


    The three sills that I will need!


    Using the belt sander I leave the tips smoth


    Done!


    Now with the caliper I trace a line in the middle of the sill, to fold in half




    I hold the sill in the vise and I hit it with a hammer to bend it


    Done!


    Now I put the sills which will place


    Once the center holes are marked, I drill them


    Now, using a drill grinder, I made a holes for the screw head


    The sills are ready, now let's test it!


    It's time to make some threads!




    Now, let's screw the stands into the chassis


    The stands are placed! Amazing!
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post #10 of 74
6/28/10 at 10:19pm
Thread Starter 
Monday June 28, 2010

Part 1
  • I ask an apology for having been so long since my last progress, but my job has been consuming a lot of time to me. I had been making some progress, but would not post them until I had something bigger and formal.
  • So be preparence, because it will be a very long post!
  • As I mentioned in my last post, I wanted to reinforce with other screw the stands. So that's what I did in later days.
  • I started doing another extra hole in the aluminum tube that will house the fan. Just as making the corresponding hole in the acrylic stands. The screws were too long and the thread I did, was shallow, so I had to cut the screws.
  • Once in place the second screw, the stands were more firm and no longer turned, obviously ...
  • Then, using a bow and jeweler's blade I cut the leftovers of the stands so that they remain smooth. Using the belt sander, I left the job done better before.
  • After this, I bought aluminum material 1/2" x 3/4" in order to connect with the peaks stand above the chassis. And an aluminum tube, to pass through off the middle the tubes it had bought previously.
  • Unfortunately, in my drill press could not do the slots needed, so I went with a friend who has tools more robust and accurate than mine.
  • Once the grooves were made, immediately I started working on the edges of these pieces, to attach the edges of the peaks and the stands.
  • Using a pointed blade I scratch some marks, then cut the excess material and finally smoothed with the belt sander!
  • Following this, I thought about an issue that had almost completely forgotten: lighting with LED's! So I went with a buddy of mine who is an expert in making PCB's (as I do not know advanced electronics, plus I never was good in that! ) Who helped me a bit with that subject!
  • I admit that I'm a little disorganized, since I went to getting the power supply without having completed the above. But fortunately had one in my room unused. So I started to disassemble it and check the size of the PCB, which was excellent: is small!
  • Unwelding some wires to remove the PCB, I withdrew the entire circuit of the power supply and started to figure out how to attach it to what I had done previously ... And with the help of some pieces of acrylic and a heat gun I made a very suitable base to hold the circuit!
  • Then, continue with the tubes that will hold through them the smaller tube and join the two parts of the stands. As with slotted parts also.
  • This work took me a little time, but I want to do well to have less errors when assembling the pieces. Fortunately it works and the assembly was quick and clean!
  • Making some holes and thread 1/8" could join the two parts of the stands. It was not easy, but I could do!
  • Finally it was time to attach the HDD and the base of the power supply below the base of the Mobo, so I set to work!
  • Using again a few holes and some threads, it was very quick and easy do it!
  • It remains to place the circuitry that controls the LED's and LED's themselves, of course ... Cut a few slots to access the I / O Panel of the Mobo, place the power button and finally, turn it on! If I missed some detail, I'll post of course!
  • Greetings and leave pictures of my progress:


    Making a hole for the extra screw


    Drilling and threading the stands also...!


    Cutting the screws


    The difference is remarkable


    Time to smooth the ends of the screws with the belt sander


    Done! There are two screws for each stand


    The three stands!


    With the help of this little friend, I cut the ends left over acrylic


    Using the "multi-chamber" I held and cut easily the acrylic


    Now, it is time to use the belt sander again to leave smooth the edge




    Done!
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