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Discussion Starter · #1 ·
I've been working on a Custom acrylic PC case that I designed.

Case features a double sidewall to allow intake air without the need of front holes; also good for cable routing. Designed to hold 2 360mm Radiators; will only use one ATM with a Y-line loop. Stealthed CD slot; will wire the eject button and activity LED to an illuminated pushbutton to preserve the clean look of the front panel.

Here are some pics of the 3D model in it's current state. I'll update with pics of the actual build as well.











Expected Hardware Requirements:
DFI Lanparty UT 680i SLI T2R/G ---- Out of pocket
Intel Q6600 G0 ---- Out of pocket
Creative X-Fi XtremeGamer ---- Out of pocket
2x BFG 8800GTX ---- Out of pocket
2x1Gb DDR2 RAM (been eying the Corsair Dominator PC2-10000)
Lite-On SATA DVD burner ---- Out of pocket
Silverstone ST1000 Modular PSU ---- Out of pocket
500+Gb SATA2 HDD ---- Out of pocket
2x X-Flow Black Ice Extreme III ---- Sponsored by DangerDen
Variable speed D5 ---- Sponsored by DangerDen
20 feet 1/2" ID Tygon ---- Sponsored by DangerDen
2x Brass Fill-port ---- Sponsored by DangerDen
TDX for LGA775 ---- Sponsored by DangerDen
Maze4 chipset block (regular block) ---- Sponsored by DangerDen
875 chipset block ---- Sponsored by DangerDen
2x 8800 GTX blocks ---- Sponsored by DangerDen
2x single-slot PCI bracket for the 8800s ---- Sponsored by DangerDen
Fill-port Reservoir ---- Sponsored by DangerDen
6x 120mm Case Fans ---- Sponsored by A.C.Ryan
Wire-sleeving ---- Sponsored by A.C.Ryan
2x dual 30cm red CCFLs ---- Sponsored by A.C.Ryan
dual 30cm UV CCFLs ---- Sponsored by A.C.Ryan
dual 20cm UV CCFLs ---- Sponsored by A.C.Ryan
Acrylic Case feet ---- Sponsored by Petra's Tech Shop
H2O Dies ---- Sponsored by Petra's Tech Shop
Biocide H2O additive ---- Sponsored by Petra's Tech Shop
AS5 ---- Sponsored by Petra's Tech Shop
36" SATA2 cables ---- Sponsored by Petra's Tech Shop
 

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Discussion Starter · #2 ·
I spent last night and today working on the motherboard panel.

Sketched panel in Pro/E


Masked the Acrylic sheet and marked the locations for the MB standoffs, RAD, and Front-panel port mounts.


With old MB to verify markings


Drilled pilot holes


Cutting the fan/RAD holes


Finished fan/Rad holes


Drilled out holes to secure the RAD


Illustration of MB standoff mounting


Drilled out and threaded holes for MB standoffs and FPIO mount


Unmasked panel


Mounting of FPIO



Added slots for cable pass-through. All cabling will be routed underneath the MB panel


Test fit of my current MB and FPIO ports





I don't have the new RAD/fans yet so I couldn't test fit those.

If anyone would like to see other detail shots/angles please LMK
 

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Discussion Starter · #3 ·
Today I started working on the drive Bays:




Laid out the parts on the masked acrylic:


The cut out panels:


Threaded side panels for drive retention mechanism (will into detail on that later):


Cut drive support rails:


Unmasked 5 1/4 bay panels:


Unmasked 3 1/2 bay panels:


I have to wait on an order from US Plastics before I can glue these parts together.

 

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Discussion Starter · #5 ·
Today I received the 1" Acrylic cubes that I'll use to assemble the main panels of the case


Drilled/Tapped the cubes so that I could screw on the panels


Closeup of one cube


Next I polished the parts for the 3.5" drive bay


3.5" Drive bays clamped and glued


 

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Discussion Starter · #7 ·
Finished the 3 1/2" drive bays


Drive retention mechanism; screws on one side with nylon spacers on the ends


Test fit with old drive


 

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Discussion Starter · #8 ·
Polished 5 1/4" drive bay panels


5 1/4" bay panels glued together


Finished 5 1/4" Drive Bays


I also polished the MB panel


Laid out side, front, and back panels


Cut out front/back panels


Cut out side panel


 

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Discussion Starter · #9 ·
Just a small update; should have more by the weekend
Looks like A.C. Ryan may be providing some sponsorship as well.
Laid out top, bottom, and other side panel


Cut out top and bottom panels


Cut out side panel


 

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Discussion Starter · #10 ·
Drilled screwholes into the first side panel


Same for the other side panel


Screwholes and fill-port hole in the top panel


Introducing the Dremel's big brother



Screwholes, drainport, and air intake slots in the bottom panel


Test-fit assembled outer panels; had to sand some of the corner blocks and panels to achieve a perfect fit


 

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Discussion Starter · #11 ·
Yesterday I received the pushbutton switches for this case; some ring-illuminated momentary switches, dot-illuminated latching switches, and a non-illuminated momentary switch


I added some stops to the panels to ensure flush edges


Laid out the back panel


Cut out back panel


Fitted into the back of the case


 

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Discussion Starter · #12 ·
This Morning I received a package from A.C. Ryan containing fans, CCFLs, and wire sleeving supplies


Time for some eye-candy

Kameleon Fan; translucent black under normal light


And Blue under UV


With the fan on:


Red Twin Overburst CCFLs


UV Twin Overburst CCFLs


And the money shot

Fan and wire sleeving in full UV splendor:


 

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Discussion Starter · #13 ·
Long awaited update


Laid out Front Panel


Cut out Front Panel


Assembled Outer Panels



Rounded the edges; note, only the outside edges have rounds
Top and Bottom Panels


Front and Back Panels


Left Panel


Right Panel


Tomorrow I'll put it back together and sand all the edges and blend the corners. I hope to get it polished tomorrow as well; But I may work on a wheeled base for it

 

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Discussion Starter · #14 ·
Just a small update today; but it give a good perspective of what the finished product will look like

Sanded the edges to blend the corners together


Assembled the panels with switches and FPIO to give an idea of how the case will look


I still have to polish up the edges and install the drive bays; then the case itself will be basically complete.

 

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Discussion Starter · #15 ·
I've also received support from Petra's Tech Shop

Here's what they sent me: Acrylic LED case feet, 3x 120mm chrome fan grills, and water additives (Biocide & Blue, Green, and Red dyes)


The LED feet and wiring harnesses


Case feet in action


One drawback to the controller for the LEDs is that it defaults to a flashing mode when it's turned on; but I'll be eliminating the controller and connecting them directly to a switched 12V line, so that won't be an issue for me.

 

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Discussion Starter · #16 ·
Some progress pics are missing since one of my memory cards died

Polished the edges of the outer panels








Also installed the PCI mounting bracket




Cut out/polished the CD slot cover


Placed in the slot on the front panel


Made some side pieces for the 5 1/4" bay


Glued them into place


With a drive in place


This evening I'll mount the drive bays; so stay tuned for another update

 

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Discussion Starter · #17 ·
Another update; The case itself is finished so next I'll have to make the base and do the wiring

Cut acrylic pieces for mounting the drive bays


Polished the mounting pieces


Glued the mounting pieces to the drive bays


Gluing the drive bays together


Finished Drive Bays


Lining up the drive bays on the top panel


Drilled screwholes at the front of the drive bays


Drilled out holes in top panel


Tapped holes in the drive bays


Screwed them together


Drilled holes at the back of the drive bays


Drilled out the holes in the top panel


Several shots of the assembled case






 

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Discussion Starter · #18 ·
I finished making my PWM fan and lighting controller. It has 8 fan channels and 4 lighting channels (1 dedicated to the fan lighting). The fan LEDs are connected to separate headers from the fan itself.

Edit: For better operation, the 0.1 uF timing capacitor should be replaced with a 100pF capacitor; this alleviates issues with the fan growling at lower speeds.

First: the circuit I used


Installed 1 fan control channel to work out the layout


Here in the US I wasn't able to find anyplace that had the MIC502 fan control IC available in a DIP package; so I had to make due with the SMD version


Soldering on leads


1 DIPicized IC


All eight channels integrated on the PCB


Added power supply as well as headers for the fan LEDs and fan LED switch


Also installed headers for the case lighting control


And a pass-through MOLEX connector


The underside of the controller


The wiring for the power connectors will also be sleeved later on in the project.

 

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Discussion Starter · #19 ·
Sleeved the wiring on the fan contoller


I also wired up and sleeved the switches for the case lighting as well as the power cables for the CCFL inverters


 

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Discussion Starter · #20 ·
Sleeved the cabling for the front panel IO


Changing gears for a while; I cut out the MDF baseboard and rounded the edges


First coat of Lacquer paint


Back to the cabling; Wired up and sleeved the HDD LED, Reset Switch, and Power Switch w/ Power LED


Back to the baseboard again; Second coat of paint


Sanded smooth


I'm hoping to be able to get a piano-quality high-gloss finish; thus the use of the lacquer.

 
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