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Crunch Build Log Bandwidth-Killer edition - Page 4

post #31 of 647
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Trying to find the best place for the PSU. As it is depicted in thumb above the easiest way to mount it is pointing down like the mobos--however the problem is this eliminates one mobo space. It also makes mounting a second PSU problematic.

This PSU is aprox. 6" x 6" x 3 1/2". Interior dimensions of a case side are 12 1/4" x 14 5/8". An ATX mobo is aprox 12" along the backplane and 9.6" wide. From this it is easy to see that 3.5" + 9.6" = 13.1" which means arranging the psu so that is exitting the case side as in a standard install will work the best and allow fitment of 4 mobos.

Since the 12" backplane edge of the mobo is to be along the bottom of the case, the PSU must then be top mounted. This will conflict with the existing plexi shield--no biggy--so another would have to be made. It follows the pattern of air flow from bottom to top. But it does make fitting additional fans very tight--about 5" of the PSU will hang into the case interior after making a hole in the 1" thick case side--leaving just enough room for 2 120mm fans on the other side of the top. And there are all those cables looping right where the fans will be.

There eventually will be 2 PSUs for the 4 mobos so the first PSU must be mounted to allow room for the next one as the rig evolves. A support will have to installed to fix these pSUs into position against the opening that will need to be cut into the case.

But before I cut into the case I want to explore all the possibilities.



The thumb above shows another way to top mount the PSU--again this only leaves room for 3 mobos. The PSU would have to be centrally located on the top edge to leave room for the mobos on either side, not much different than the same postion on the bottom--the only benefit is that the case would not be cut.



The thumb above shows how mounting the PSU "conventionally" will leave enough space for an ATX mobo. And still have 3/4" for the filter.



The Thumb above gives a good idea of how two PSUs can be mounted side by side through the case--as you can see the wires will need some serious management and there will barely be room for 2 120mm fans.



Above is the original idea for Crunch final revision--watercooled with a top mounted radiator--somehow I doubt a 2X120mm heatercore would be sufficient--and that is all the space there is up top after mounting the PSUs as depicted.

The only way I know to keep the top open is to bottom mount the PSUs--this would mean mounting the mobos up as high as possible in the case, making cabling to the backplanes a real pain to get at.

If I eliminate one mobo slot and flush mount the PSU in the case like this: I still have space issues with the heatsink or Waterblock. Any expansion cards might very well conflict with the PSU location if the PSUs are mounted that way on the bottom too.

I would appreciate any input on this before I break out the jigsaw...
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post #32 of 647
Wow that looks great! Only one thing comes to mind though... Don't you think it would better to leave the top open (still covered by the wood panel though) instead of having that tiny fan and plexiglass? It seems like unless that fan is a jet engine it would be better to let the heat rise naturally out the top.
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post #33 of 647
Quote:
Originally Posted by Fishie36
Wow that looks great! Only one thing comes to mind though... Don't you think it would better to leave the top open (still covered by the wood panel though) instead of having that tiny fan and plexiglass? It seems like unless that fan is a jet engine it would be better to let the heat rise naturally out the top.
I think that Fishie36 is right... Without the acrilic panel you will have a better dissipation of the heat...

I'm anxious to see that project finished.....
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post #34 of 647
You probably don't want to make Crunch higher, but if that's no problem, why not make an extra box the same size as Cruch (length x width) and about 4 inches high or so. This box will sit underneath Cruch, and houses the PSUs and possibly the hard drives. Cables can be routed from the lower box to Cruch (mmm Antec P180 style, but then better )

Just thinking out loud.

PS: Druid, my first FAQs finally posted
    
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post #35 of 647
Thread Starter 
Well the purpose of the plexi shield is to harness all of the pull of that "tiny" fan. 70 cfm is pretty respectable so I don't know if tiny is appropriate. But part of the reason for trying out this design is to test some theories I have about optimal airflow--how much air really needs to move through the case? If the PSUs are top mounted and drawing in with their 2 fans each that is 4 fans already pulling air out of the case. Replacing the "tiny" fan with 2 135 cfm nidec server fans should provide ample air flow for 4 mobos. No way to know until I try it out.

The top panel provides a surface to mount the server fans onto and also stops reversion of air back through the fans. I theorise that a top panel with blowholes will provide more airflow than simply hanging some fans in the opening.

Still in a quandary about whether or not to cut into the case. I want the entire piece to remain discrete--additional compartments are not part of my aesthetic package.

One question that keeps nagging at me is: how important is it to have 4 mobos? would 2 or 3 be enough to achieve my goal? If I scale down the project at this point mounting the hardware is super simple--the PSU already has a flange so I could surface mount it to the interior of the case and be done with it--no cutting ,no brackets. Later as Crunch grows I could take additional steps to relocate the hardware and accomodate additional mobos.

But that sort of leaves me cold...I really would like to make this as challenging as possible and figure it out...watercooling and all.

Need to keep studying it.
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post #36 of 647
Thread Starter 
Major progress--PSU and fan is installed as well as filter and mobo track.

Started off marking the angles with my combo square:


Then cut it with my Fein vibrasaw:


But the cordless circular saw was faster:


Here are the tools:


This is what I was talking about in the Footstool Folder thread for trapping the mobo "tray":


Pop rivetting them:


4 pieces ready to install:


Drilling them for mounting holes:


Mounting the first one along the bottom edge of the case interior:


All four installed:


Cutting filter material :


Filter installed in the C channel along the bottom edge of the case:


Top view--purdy:


Installing the angle pieces that support the PSU and fan:


Fitting the notched piece of C channel that traps the PSU:


Fitting the PSU:


Topview of the mounted PSU:


Recutting the plexiglas top panel into a 6" by 6" square:


Here it is installed with pop rivets:


Here is Crunch with a PSU installed and a 70 cfm 110VAC 120mm fan mounted just below and beside the PSU exhaust:
]

As you can see I left exactly enough room to do it again with another identical PSU and fan:


So that's the latest. Next I will tackle the drop-in mobo trays. There is exactly 1/2" clearance between the fan and the top edge of the mobo as oriented in this case.

What do you think about Crunch so far?
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post #37 of 647
I'd like to place my order. It's looking great, keep up the hard work and 'grats on the kiddo!
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post #38 of 647
Quote:
Originally Posted by CyberDruid
Major progress--PSU and fan is installed as well as filter and mobo track.

Started off marking the angles with my combo square:
Think you posted the wrong picture ^^. Congrats if its yours though...
    
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post #39 of 647
To cool 4 CPUs, I can tell you right now, you're going to need two Bonnie cores. So the water cooling aspect is going to get interesting. Since the area is small, only 1 pump should be needed. The only reason I used 2 was due the large amount of tubing I used. So, how many PSU's are you going to end up using? This thing is looking soo good.
post #40 of 647
looks nice so far, i love it

good luck with it.

(whoo 200th post!!)
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