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Discussion Starter #21
<b>8. FRONT PANEL MODDING AND FRONT FAN MOUNTING</b><br><br>
Alright ladies and gents, here's the moment we've all been waiting for. The tricksy false front panel! This is probably the most complicated, metalwise, of the work I'm doing on this particular case. I have very limited room to work with, and many things could go wrong here. So let's start with some even moar careful measurement.<br><br>
I admit it, I stared at that front panel for hours until I didn't trust my own measurements. So I says to myself. <i>"Self, mayhap someone's made a template for just such an occasion."</i> And after a quick Googling (don't tell the wife) I found this:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023006/"><img alt="" class="lightbox-enabled" data-id="2023006" data-type="61" src="http://www.overclock.net/content/type/61/id/2023006/width/350/height/700/flags/LL" style="; width: 350px; height: 266px"></a><br><br><br>
My thanks to MNPCTech for publishing such a useful template. Technically, it's for a radiator, but it works beautifully for a pair of 120mm fans too. You can find other templates like this in PDF format here:<br><br><a class="bbcode_url" href="http://mnpctech.com/pc-cooling-fan-templates.html" target="_blank">http://mnpctech.com/pc-cooling-fan-templates.html</a><br><br>
I started out by printing it <b>(NO SCALING)</b> on thick cardstock, then cut it out to fit. Here's what it looks like setting in there.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023008/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023008" data-type="61" src="http://www.overclock.net/content/type/61/id/2023008/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
You may notice something else... the presence of a metal plate on the left there. That is a nailing plate from Lowes Home Improvement, $0.83 and the perfect size for my purposes. The only problem was some of the pass-through holes in the front panel had rolled edges, which I had to grind down.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023009/"><img alt="" class="lightbox-enabled" data-id="2023009" data-type="61" src="http://www.overclock.net/content/type/61/id/2023009/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
That done, I could drill the first hole through plate and panel and temporarily mount it with a machine screw and nut. It will eventually be attached with pop rivets. Haven't decided whether to do that before or after painting.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023010/"><img alt="" class="lightbox-enabled" data-id="2023010" data-type="61" src="http://www.overclock.net/content/type/61/id/2023010/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023011/"><img alt="" class="lightbox-enabled" data-id="2023011" data-type="61" src="http://www.overclock.net/content/type/61/id/2023011/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
And with that out of the way, I could finish drilling the other mount points for the plate and fixing it in its final position.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023012/"><img alt="" class="lightbox-enabled" data-id="2023012" data-type="61" src="http://www.overclock.net/content/type/61/id/2023012/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
Next step was to drill out all the fan screw holes and the center hole to ensure the hole saw wouldn't slip. Found out the hard way I made one error (see next photo). Bit kept jumping on that corner hole, turned out I forgot to grind down the rolled edge there.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023013/"><img alt="" class="lightbox-enabled" data-id="2023013" data-type="61" src="http://www.overclock.net/content/type/61/id/2023013/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
Okay, time to break out the big guns. My 4.5" hole saw. But first, let's apply some lessons learned and make a "Metallic Debris Deflection and Containment Device" or as I like to call it, the MDDCD or, in the vernacular, a bunch of (expletive deleted) cardboard and a plastic bin lid.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023014/"><img alt="" class="lightbox-enabled" data-id="2023014" data-type="61" src="http://www.overclock.net/content/type/61/id/2023014/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
And let's make sure we are clamped down well, sandwiched between wooden blocks to prevent deforming the panel. And again, this turned out to be a good thing, as even with my gentle pressure the <b>hole saw jammed once</b> and would have likely sliced through my arm or taken off a finger otherwise. <b><span style="text-decoration:underline;">Hole Saw + Sharp Panel = HIGH RISK OF INJURY</span></b><br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023015/"><img alt="" class="lightbox-enabled" data-id="2023015" data-type="61" src="http://www.overclock.net/content/type/61/id/2023015/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023016/"><img alt="" class="lightbox-enabled" data-id="2023016" data-type="61" src="http://www.overclock.net/content/type/61/id/2023016/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023017/"><img alt="" class="lightbox-enabled" data-id="2023017" data-type="61" src="http://www.overclock.net/content/type/61/id/2023017/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
And then grinding off the burrs.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023018/"><img alt="" class="lightbox-enabled" data-id="2023018" data-type="61" src="http://www.overclock.net/content/type/61/id/2023018/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
Second oops. That rolled edge before? Too close to the fan screw hole. The bit slipped and chewed it out. I'll have to do something to mitigate that at some point.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023019/"><img alt="" class="lightbox-enabled" data-id="2023019" data-type="61" src="http://www.overclock.net/content/type/61/id/2023019/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023020/"><img alt="" class="lightbox-enabled" data-id="2023020" data-type="61" src="http://www.overclock.net/content/type/61/id/2023020/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
So here's the cleaned up final panel. I won't say this is professional by any stretch, but overall, looks pretty good I think.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023021/"><img alt="" class="lightbox-enabled" data-id="2023021" data-type="61" src="http://www.overclock.net/content/type/61/id/2023021/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023022/"><img alt="" class="lightbox-enabled" data-id="2023022" data-type="61" src="http://www.overclock.net/content/type/61/id/2023022/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
And hooked up a temporary fan to check out how it's going to look. It'd be even cooler if I had more than one spare fan. ;-)<br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023023/"><img alt="" class="lightbox-enabled" data-id="2023023" data-type="61" src="http://www.overclock.net/content/type/61/id/2023023/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023024/"><img alt="" class="lightbox-enabled" data-id="2023024" data-type="61" src="http://www.overclock.net/content/type/61/id/2023024/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
Final Thoughts:<br><br>
The panel had several pass-throughs, rolled edges, and raised vents that made drilling <i>exactly</i> where I wanted to challenging. If I had it to do all over again, I might have just cut the whole drowning middle out of the panel, cut the fan mounts into a virgin piece of sheet steel, and then mounted it in the gutted front panel. As it is, I was only <b>1mm off</b> on the top hole, bottom hole was perfect, and only one fan screw hole was hosed. Not bad overall.<br><div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/10#post_22290804" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>BruceB</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/10#post_22290804"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br>
Noice! <img alt="thumb.gif" class="bbcode_smiley" src="http://files.overclock.net/images/smilies/thumb.gif"></div>
</div>
<br>
And again, thank you.
 

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Looks good, I like the look of front mounted fans. <img alt="thumb.gif" class="bbcode_smiley" src="http://files.overclock.net/images/smilies/thumb.gif">
 

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Discussion Starter #23
<b>9. MOD FRONT BEZEL AND TAKE STOCK</b><br><br>
FIrst, I needed to finish up modifying the 5.25 Drive Cage so it would fit over the upper front fan. This was pretty straightforward.<br><br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023811/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023811" data-type="61" src="http://www.overclock.net/content/type/61/id/2023811/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023809/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023809" data-type="61" src="http://www.overclock.net/content/type/61/id/2023809/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
Basically all I did was set it just above the fan, and trace out the overlap. Then it was off to use the Dremel cutoff blade and then grind down the burs. When I was finished, the new plate I installed on the front panel only extended about 5mm into the lower 5.25 bay. That shouldn't be an issue, and I can cut notches if needed when I get to building the control panel there.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023849/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023849" data-type="61" src="http://www.overclock.net/content/type/61/id/2023849/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023851/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023851" data-type="61" src="http://www.overclock.net/content/type/61/id/2023851/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023852/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023852" data-type="61" src="http://www.overclock.net/content/type/61/id/2023852/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br><br>
So, let's move on to the main event. First I screwed the front bezel onto my newly bored out front panel.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023853/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023853" data-type="61" src="http://www.overclock.net/content/type/61/id/2023853/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023854/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023854" data-type="61" src="http://www.overclock.net/content/type/61/id/2023854/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
I spent some time trying to figure out the best way to transfer the hole in the panel onto where I wanted it on the front bezel, starting out trying to make a loop out of cardstock the size of the hole and then tracing it.<br><br>
Then it struck me. "Stupid!" I said to myself. "The front metal panel is your brace and template! Just flip it upside down and drill through the existing hole!"<br><br>
And so I did. Took a bit of bracing to keep the plastic panel level, as you can see here:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023855/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023855" data-type="61" src="http://www.overclock.net/content/type/61/id/2023855/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023856/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023856" data-type="61" src="http://www.overclock.net/content/type/61/id/2023856/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br><i>LESSON LEARNED: I should have glued down the 3.5" Bay Panel and the lower flip-up door. I ended up with those flying off instead of cutting cleanly, and then had to glue them and redrill those spots.</i><br><br>
But overall, it worked very well, as you can see here.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023857/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023857" data-type="61" src="http://www.overclock.net/content/type/61/id/2023857/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023858/"><img alt="AppleMark" class="lightbox-enabled" data-id="2023858" data-type="61" src="http://www.overclock.net/content/type/61/id/2023858/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
My next step will be to fill the gap between the front bezel and the metal panel. On the advice of others here, I'm going to try using expanding foam for that, and then rebore the holes.<br><br><i>LESSON LEARNED: In retrospect, I probably should have done that along with gluing the bits before drilling the first time. It would have stabilized the plastic and probably gotten me a cleaner cut.</i><br><br>
Then, just to see how far I've come, I mounted the LED fan and other components and gave it a test run for appearance. I temporarily stuck the power and reset buttons in the 5.25" bay. I'll be replacing those buttons completely down the road.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023859/"><img alt="" class="lightbox-enabled" data-id="2023859" data-type="61" src="http://www.overclock.net/content/type/61/id/2023859/width/600/height/800/flags/LL" style="; width: 600px; height: 450px"></a><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023860/"><img alt="" class="lightbox-enabled" data-id="2023860" data-type="61" src="http://www.overclock.net/content/type/61/id/2023860/width/600/height/800/flags/LL" style="; width: 600px; height: 450px"></a><br><br>
So let's do a before and current status comparison, shall we?<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023874/"><img alt="" class="lightbox-enabled" data-id="2023874" data-type="61" src="http://www.overclock.net/content/type/61/id/2023874/width/1000/height/500/flags/LL" style="; width: 750px; height: 500px"></a><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2023875/"><img alt="" class="lightbox-enabled" data-id="2023875" data-type="61" src="http://www.overclock.net/content/type/61/id/2023875/width/1000/height/500/flags/LL" style="; width: 1000px; height: 450px"></a><br><br>
For my first attempt at this, I am very satisfied.
 
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Excellent work dude and great narrative, this is turning into one of my favourite case mod logs!
 

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Looking good! I like this mod a lot!
 

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Discussion Starter #26
<div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/20#post_22298682" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>Brian18741</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/20#post_22298682"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br>
Excellent work dude and great narrative, this is turning into one of my favourite case mod logs!</div>
</div>
<br><div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/20#post_22298869" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>nickcnse</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/20#post_22298869"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br>
Looking good! I like this mod a lot!</div>
</div>
<br>
Thank you both very much! It's encouraging to see that people are enjoying not only the mod but the way I'm posting it. Part of my intent is to have enough detail that another noob like me can learn something from it too. ;-)
 

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<a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024632/"><img alt="" class="lightbox-enabled" data-id="2024632" data-type="61" src="http://www.overclock.net/content/type/61/id/2024632/width/500/height/1000/flags/LL" style="; width: 380px; height: 280px"></a><br>
Looks so clean, as if it was done by a pro! +rep <img alt="thumb.gif" class="bbcode_smiley" src="http://files.overclock.net/images/smilies/thumb.gif">
 

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Discussion Starter #28
<div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/20#post_22301720" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>rRansom</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/20#post_22301720"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br><a class="spoiler-link H-spoiler-toggle" href="#"><strong>Warning: Spoiler!</strong> <span class="spoiler-help">(Click to show)</span></a><div class="spoiler-hidden"><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024632/"><img alt="" class="lightbox-enabled" data-id="2024632" data-type="61" src="http://www.overclock.net/content/type/61/id/2024632/width/500/height/1000/flags/LL" style="; width: 380px; height: 280px"></a></div>
Looks so clean, as if it was done by a pro! +rep <img alt="thumb.gif" class="bbcode_smiley" src="http://files.overclock.net/images/smilies/thumb.gif"></div>
</div>
<br>
*sobs* My first ever Rep!!! And my favorite memephoto too!<br><br>
*bows* I thank you.
 

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You're welcome, buddy - you deserved it. Keep us posted on the progress, I'm sure someone else will come to appreciate your work.
 

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<b>10. Drive Cage Vents, Front Panel Foam, and Test Paint</b><br><br>
Okay, so this one is a bit of a hodgepodge, because I had to wait for the foam to dry, and the paint to dry between applications, and I wanted to see what I could do about drive cage air-flow.<br><br>
Here's the drive cage:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024655/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024655" data-type="61" src="http://www.overclock.net/content/type/61/id/2024655/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
The problem was, this sits directly behind the front case fans, and as you can see by the circles, it impedes the air flow. Modern cages in that orientation have vents or slots so air can freely flow into the case with minimal backpressure.<br><br>
I posted on another thread asking for advice regarding cutting holes, slots, windows, or even removing some of the bay locations. Thanks to their kind advice, I settled on slots and keeping all bays available. So here we go.<br><br>
My first step was to mark where I wanted the slots between the bays. To keep a clean look, I made them all extend the same distance even though some were not in the direct air path. I also tried to sketch in rounded corners.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024875/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024875" data-type="61" src="http://www.overclock.net/content/type/61/id/2024875/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
Now for the Dremel. I used the cutoff disks to cut the straight lines, and as the disks wore down I did the narrower ends, then bent and snapped the rough pieces out.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024876/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024876" data-type="61" src="http://www.overclock.net/content/type/61/id/2024876/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024877/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024877" data-type="61" src="http://www.overclock.net/content/type/61/id/2024877/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024881/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024881" data-type="61" src="http://www.overclock.net/content/type/61/id/2024881/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
After that, I used a grindstone and sanding drum on the Dremel to smooth out the corners and remove burrs. It could use another cleanup, but looks pretty good.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024872/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024872" data-type="61" src="http://www.overclock.net/content/type/61/id/2024872/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
Much improved.<br><br>
Now this was just a sideshow while I waited for my expanding foam to do its thing.<br><br>
First I stencilled the mounting post location onto a piece of paper, which I taped to a piece of scrap board and wrapped some plastic sheet around it (so the foam doesn't bond to the board).<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024890/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024890" data-type="61" src="http://www.overclock.net/content/type/61/id/2024890/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
I drilled out the marks where the posts would go, and that allowed me to mount the bezel flush on the board.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024891/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024891" data-type="61" src="http://www.overclock.net/content/type/61/id/2024891/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
Now to spray in the expanding foam. I don't think anyone will be surprised to know that I completely overdid it.<br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024893/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024893" data-type="61" src="http://www.overclock.net/content/type/61/id/2024893/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024894/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024894" data-type="61" src="http://www.overclock.net/content/type/61/id/2024894/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
And here's the final result. I had to add extra bracing to keep the bezel from lifting off the board:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024897/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024897" data-type="61" src="http://www.overclock.net/content/type/61/id/2024897/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024898/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024898" data-type="61" src="http://www.overclock.net/content/type/61/id/2024898/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
Still waiting for it to cure completely, then I'll redrill out the center, clean it up, reinforce it a bit, and sculpt the fan tubes.<br><br>
EDIT: OOPS I forgot to post pictures of the test painting. I did minimal prep on these pieces. Mostly I just wanted to see what it would look like.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024938/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024938" data-type="61" src="http://www.overclock.net/content/type/61/id/2024938/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024939/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024939" data-type="61" src="http://www.overclock.net/content/type/61/id/2024939/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2024940/"><img alt="AppleMark" class="lightbox-enabled" data-id="2024940" data-type="61" src="http://www.overclock.net/content/type/61/id/2024940/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a>
 

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Wait, have I missed something here? What's the expanding foam for?<br><br>
Looking good, that HDD Cage is so good it Looks stock! <img alt="thumb.gif" class="bbcode_smiley" src="http://files.overclock.net/images/smilies/thumb.gif">
 

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Discussion Starter #32
<b>11. FOAM SUBSTRATE COMPLETE</b><br><br>
In which Bruce finds out why I'm spraying expanding foam into the front bezel!<br><div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22304104" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>BruceB</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22304104"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br>
Wait, have I missed something here? What's the expanding foam for?<br><br>
Looking good, that HDD Cage is so good it Looks stock! <img alt="thumb.gif" class="bbcode_smiley" src="http://files.overclock.net/images/smilies/thumb.gif"></div>
</div>
<br>
Funny you should ask... (And thanks for the compliment on the drive cage. There are some spots where I slipped, and it's not quite perfect when you look very closely, but not bad for hand tools I think.)<br><br>
So what I did was, I sprayed expanding foam (Great Stuff) into the cavity of the front bezel to make a substrate for something more solid. After it cured, I cored it out with an exacto knife (and cut myself) as you see here:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025187/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025187" data-type="61" src="http://www.overclock.net/content/type/61/id/2025187/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025188/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025188" data-type="61" src="http://www.overclock.net/content/type/61/id/2025188/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
Then I took it back (yet again) to the hole saw and just trimmed out the excess in the middle.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025190/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025190" data-type="61" src="http://www.overclock.net/content/type/61/id/2025190/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
The result was pretty sweet, I think. A perfect matching "tube" lined up with the front bezel, and it adds almost no weight to the bezel.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025191/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025191" data-type="61" src="http://www.overclock.net/content/type/61/id/2025191/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
And a back view:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025193/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025193" data-type="61" src="http://www.overclock.net/content/type/61/id/2025193/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025195/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025195" data-type="61" src="http://www.overclock.net/content/type/61/id/2025195/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
EDIT: The more I stare at it, the more I realize that top hole is a few mm's off. I'm going to have to drill that out a bit more and fill it on the other side. Then some sanding and filler work on the front bezel, and finally painting that baby.<br><br>
I'll post a photo of the installed front bezel with the foam later this evening.
 

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That stuff looks like it worked perfect! Keep up the good work!
 

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Impressive work. Are you going to bondo/fill the bore of the foam tubes? It looks really too. Keep up the work
 

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Discussion Starter #35
<b>12. FIRST SETBACK AND RECOVERY</b><br><br>
Well it looks like either the "Great Stuff" foam was not fully cured when I trimmed it, or the air flow made it dry too quickly, or it just naturally does this, but when I checked this morning, it had contracted and the foam "tube" had widened. :-(<br><div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22305700" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>nickcnse</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22305700"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br>
That stuff looks like it worked perfect! Keep up the good work!</div>
</div>
<div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22307711" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>animal0307</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22307711"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br>
Impressive work. Are you going to bondo/fill the bore of the foam tubes? It looks really too. Keep up the work</div>
</div>
<br>
Thank you both, but it looks like I posted too soon. Overnight, it changed to this:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025917/"><img alt="" class="lightbox-enabled" data-id="2025917" data-type="61" src="http://www.overclock.net/content/type/61/id/2025917/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025918/"><img alt="" class="lightbox-enabled" data-id="2025918" data-type="61" src="http://www.overclock.net/content/type/61/id/2025918/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
On top of that, the fact that the top hole was about 2-3mm too far to the left was making me nuts. <img alt="tongue.gif" class="bbcode_smiley" src="http://files.overclock.net/images/smilies/tongue.gif"><br><br>
So let's regroup a bit. Clearly I need something better in that hole than expanding foam. Based on advice from TLHarrell and after looking at some stuff from MNPCTech, I decided I really needed some sort of insert, supported by the foam.<br><br>
Now, Obviously, I could have gone online and ordered premade ones. MNPCTech, PerformancePCs, CoolerGuys, and FrozenCPU all sell "fan ducts". But where's the fun in that??? I'm trying to use, as much as possible, salvaged parts and easily available substitutes. After a short trip to the hardware store with a paper template of the holes, I found this:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025926/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025926" data-type="61" src="http://www.overclock.net/content/type/61/id/2025926/width/350/height/700/flags/LL" style="; width: 222px; height: 700px"></a><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025925/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025925" data-type="61" src="http://www.overclock.net/content/type/61/id/2025925/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025927/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025927" data-type="61" src="http://www.overclock.net/content/type/61/id/2025927/width/350/height/700/flags/LL" style="; width: 350px; height: 286px"></a><br><br>
That's right, it's a 6' long piece of Schedule 40 PVC Pipe, 4" Inner Diameter. And it has an Outer Diameter of ... you guessed it, 4.5". It fits literally like a glove. Heck I could have friction fit it into place in the hole saw cut. Total cost, $10 for enough to do 20-30 ducts. They also carried 3' lengths for about $7 but unfortunately were sold out of that length.<br><br>
But we still had that pesky mis-drilled hole. 2-3mm off, remember? Driving our poor modder nuts, right? Well let's fix that too.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025935/"><img alt="" class="lightbox-enabled" data-id="2025935" data-type="61" src="http://www.overclock.net/content/type/61/id/2025935/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
Offset the piece just a hair, and shaved off another 2.5mm from one side, careful not to damage the top and bottom, which are wayyy thin at this point.<br><br>
Now to place our cut pipe in the holes and temporarily lock them in place with a bit of superglue. I also put a thin piece of cardboard underneath to make sure there would be a small gap for a future filter.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025937/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025937" data-type="61" src="http://www.overclock.net/content/type/61/id/2025937/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025938/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025938" data-type="61" src="http://www.overclock.net/content/type/61/id/2025938/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025939/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025939" data-type="61" src="http://www.overclock.net/content/type/61/id/2025939/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
And on once those are firmly fixed in place, I flipped it over and spray-foamed the remaining gaps to firmly lock the new "fan ducts" into place.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025945/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025945" data-type="61" src="http://www.overclock.net/content/type/61/id/2025945/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025946/"><img alt="AppleMark" class="lightbox-enabled" data-id="2025946" data-type="61" src="http://www.overclock.net/content/type/61/id/2025946/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br><br>
My OCD is now satisfied, and I think it should be simple to trim the fronts as desired and use fiberglass or bondo to sculpt it. Based on comments, I'm now leaning more toward fiberglass, even though I'm pretty intimidated by it...
 

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Sweet work, i'm for sure loving this build.
 

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Discussion Starter #37
<div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22307874" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>nickcnse</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22307874"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br>
Sweet work, i'm for sure loving this build.</div>
</div>
<br>
And thank you again for the feedback. I'm having a blast, but the encouragement means a lot.<br><br>
Here's a "Starting vs Progress So Far" photo, just for giggles.<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2025983/"><img alt="" class="lightbox-enabled" data-id="2025983" data-type="61" src="http://www.overclock.net/content/type/61/id/2025983/width/500/height/1000/flags/LL" style="; width: 500px; height: 330px"></a>
 

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I'd fill the gaps with JB Weld. It's a lot easier to use than fiberglass. Mold it like putty, shove it in place, smooth with a wet fingertip. Let it dry and it's easy enough to grind and sand on.
 

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Discussion Starter #39
<div class="quote-container" data-huddler-embed="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22309084" data-huddler-embed-placeholder="false"><span>Quote:</span>
<div class="quote-block">Originally Posted by <strong>TLHarrell</strong> <a href="/t/1489627/case-mod-relic-my-first-case-mod/30#post_22309084"><img alt="View Post" class="inlineimg" src="/img/forum/go_quote.gif"></a><br><br>
I'd fill the gaps with JB Weld. It's a lot easier to use than fiberglass. Mold it like putty, shove it in place, smooth with a wet fingertip. Let it dry and it's easy enough to grind and sand on.</div>
</div>
<br>
Thank you. I'll probably do that instead.
 

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Discussion Starter #40
<b>13. NEW FANS</b><br><br>
Today was a happy day, because my Yate Loon LED fans arrived!<br><br>
I did a lot of digging to find out what fans were the best "bang for the buck" while also being quiet. I settled on the Yate Loon D12SL's. They run at low speeds but have good airflow.<br><br>
Problem was, I wanted a particular color, and everyone seemed to be out of them. I finally found what I was looking for at PerformancePCs at a very reasonable price. They arrived today and I immediately installed them in the newly ported front panel, and in the new back panel hole. I think it looks just incredible.<br><br>
Angle view:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2026336/"><img alt="AppleMark" class="lightbox-enabled" data-id="2026336" data-type="61" src="http://www.overclock.net/content/type/61/id/2026336/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2026337/"><img alt="AppleMark" class="lightbox-enabled" data-id="2026337" data-type="61" src="http://www.overclock.net/content/type/61/id/2026337/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
And front view:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2026338/"><img alt="AppleMark" class="lightbox-enabled" data-id="2026338" data-type="61" src="http://www.overclock.net/content/type/61/id/2026338/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2026339/"><img alt="AppleMark" class="lightbox-enabled" data-id="2026339" data-type="61" src="http://www.overclock.net/content/type/61/id/2026339/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
Closeup:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2026340/"><img alt="AppleMark" class="lightbox-enabled" data-id="2026340" data-type="61" src="http://www.overclock.net/content/type/61/id/2026340/width/350/height/700/flags/LL" style="; width: 350px; height: 467px"></a><br><br>
And view of interior through a 5.25" Drive Bay:<br><br><a class="H-lightbox-open" href="http://www.overclock.net/content/type/61/id/2026341/"><img alt="" class="lightbox-enabled" data-id="2026341" data-type="61" src="http://www.overclock.net/content/type/61/id/2026341/width/350/height/700/flags/LL" style="; width: 350px; height: 263px"></a><br><br>
Question for you folks.<br><br>
Those fan ducts, I kindof like them sticking out like they are. If I leave them like that, and just build up a gentle slope from the base to the top, do you think it will look okay, or should I cut off some of the amount that is sticking out? It sticks out about 1.2 cm (0.5").
 
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