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Project: Voyager - Page 12

post #111 of 159
Project Voyager 2.0!

Alex and I have finally begun discussing how we are going to complete Project Voyager. We both needed an almost 6-month break from this project; I think we were both “burnt” from spending over 1000 hours spent on this single project between August 2010 and July 2012.

Our time away from Project Voyager has really helped. Alex and I are once again communicating via phone and e-mail on everything we learned about designing such a complex computer case and water cooling system. We have made many positive revisions from the original CAD designs, but we also made many mistakes. During one of our conversations, one of us (I can’t remember who) asked this question:

“Can you imagine how good this case would be if we redesigned and rebuilt the case from scratch?”

At first, I thought we were joking. I have a feeling that, at a subconscious level, we both wanted to another crack at building our “dream” case. We have begun redesigning and rebuilding the case, which is now called “Project Voyager 2.0”. Alex will provide a more detailed post at a later date. The new case design will look almost the same on the outside. The changes are internal. Below is a brief list of the changes we will be making:

(1) The new case design will allow us to disassemble the case into two pieces for transportation. Trying to transport a single, 400+ pound crate has proven to be extraordinarily difficult. Moving along level surfaces is easy thanks to the casters. I never thought to consider going up and down stairs. My home does not have an elevator!  The two computers will now be placed on the upper half of the case, while the Voyager engineering model will be at the bottom. Since the Voyager model requires a power source, I have purchased a 4th power supply: Corsair AX750. Each half of the case will have its own sources of power. This makes disassembling and assembling the case much easier; the entire process will take about 10 minutes.

(2) The entire case has a new, and very strong, aluminum skeleton. *All* acrylic panels will be mounted directly onto aluminum. Any opening panels will have an aluminum frame. This new approach will address the problem of the acrylic panels bowing and bending in certain places on the case. Please remember that the size of these panels is very large and acrylic will begin to bend, but not weaken or break, after a very short distance. I have decided to make an additional investment to make sure that no acrylic panel, large or small, will bend thanks to a sophisticated aluminum skeleton.

(3) All but 4 cathodes will be replaced with LEDs. As I stated in a prior post, the cathodes have proven to be too unreliable when transporting the case (they are damaged too easily). Over 60 cathodes require too much power, and only one or two large cathodes can be successfully connected to an 8-way inverter. If you try to connect 8 large cathodes to a single inverter, the cathodes do not illuminate. The amount of heat produced from an inverter is extraordinary. If we keep the inverters, they need to be water-cooled!

(4) The length of the wiring inside the case, which is between 5,000 and 6,000 feet (that’s not a typo), requires considerably more space for organization. A large cavity inside the case will organize all of the wiring. Also, 90% of the wiring will be hidden from view. We cannot sleeve over 5,000 feet of wiring. The wires themselves consume considerable space. When you add the space of sleeving, the amount of space required triples! All exposed wires will be sleeved. Otherwise, we will have color-coded wiring that remains hidden behind panels inside the case. Those panels can be removed to perform maintenance if necessary. Do you know what’s funny? We need about 12 different colors to provide the proper color-coding strategy we need. I have only found 10 different colors online! The cost of the upgraded wiring alone will be about $500.

(5) All of the internal wiring will require ventilation. Small wiring usually produces so little that it’s negligible. However, over a mile of wiring collectively produces more heat than you think! Additional fans may be installed internally to ensure sufficient ventilation is channeled over the wiring.

(6) The “power tower” that provides all of the electrical power for the case tips over very easily. We did not take into account the combined weight of two isobar power strips (with 10 outlets each) and 10 power bricks. The combined weight is a whopping 20 pounds! We have to install a solid aluminum block inside the power tower to provide an effective counterweight for proper balance.

We will have more posts and photos on the new design later this month. I plan on traveling to Pennsylvania to assist Alex with building case as I have done in the past. Our goal is to have the case 100% complete before the FITES gaming event (in Pennsylvania) in February. We will be unveiling the case to the public for the first time at FITES. The only other place you can see this build is exclusively on OCN.

Looking forward to completing this project! Many, many thanks to all OCN and non-OCN members who have read, commented, and supported this project over the past 2 years. When we read your comments on this thread, even short statements, *really* helps Alex and I stay motivated to complete this project. Your feedback and support has been extraordinarily helpful and *greatly* appreciated! thumb.gif

Vailen
    
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post #112 of 159
Looking awesome! Great job!
post #113 of 159
Sweety and I are engaged!

I want to share with my friends on OCN that "Sweety" and I are engaged! I am blessed with a fiance who is enthusiastically supportive of a massive, complicated, and very expensive computer case! My Sweety loves sci-fi like Star Trek, Stargate, and Battlestar Galactica, and LOVES computer builds like she sees on OCN! How many guys out there can say that? I am a VERY lucky man!

Vailen
    
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post #114 of 159
HOLY ####! That is the *best* scratch build i've ever seen. And congrats on your engagement! Awesome biggrin.gif
post #115 of 159
Congrats!
 
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post #116 of 159
Quote:
Originally Posted by Vailen View Post

Sweety and I are engaged!
I want to share with my friends on OCN that "Sweety" and I are engaged! I am blessed with a fiance who is enthusiastically supportive of a massive, complicated, and very expensive computer case! My Sweety loves sci-fi like Star Trek, Stargate, and Battlestar Galactica, and LOVES computer builds like she sees on OCN! How many guys out there can say that? I am a VERY lucky man!
Vailen

major grats in both fields... i have neither had a GF that liked computers, nor a single case with a mile of wiring tongue.gif... keep up the good work and i cant wait to see what you guys come up with smile.gif... would be awsome to see you get some sponcers smile.gif
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post #117 of 159
All the best on your engagement!
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post #118 of 159
Wow! That thing is beastly! 400LBS? good thing for the re-design wink.gif I'm sure it'll turn out sweet if you guys keep up the good work!
Congratulations on the engagement thumb.gif
Quote:
Originally Posted by eskamobob1 View Post

major grats in both fields... i have never had a GF, not a single one sad-smiley-002.gif ..... keep up the good work and i cant wait to see what you guys come up with smile.gif... would be awsome to see you get some sponcers smile.gif

*fixed








Just kidding Bob wink.gif
.
Edited by bob808 - 12/1/12 at 1:10am
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post #119 of 159
Quote:
Originally Posted by bob808 View Post

Wow! That thing is beastly! 400LBS? good thing for the re-design wink.gif I'm sure it'll turn out sweet if you guys keep up the good work!
Congratulations on the engagement thumb.gif
*fixed
Just kidding Bob wink.gif
.

hey... just cause we have the same name doesnt mean you can bully me sad-smiley-002.gif...lol tongue.gif

PS. my real name isnt bob wink.gif
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post #120 of 159
Thread Starter 
Massive update and many pictures to come. We've spent at least 30 hours over the past week just starting the new aluminum frame for this. 50 aluminum bars, and about 1056 drilled and tapped holes later, we're starting to see a very very strong frame come together.
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