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The Fabricat0r
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5,933 Posts
Discussion Starter #1
Final pictures!

Hello everyone!

It's been a while since I posted a project on OCN so I figured I should share something new I am starting on.
It's a mITX mod inspired by some chrome hubcaps I picked up. These particular hubcaps are nicknamed "Baby Moons", hence the project name.

I'm not a 3D wiz but here are some basic sketchup models to get an idea.

BM-001.jpg

BM-002.jpg

The hubcap/side panels are ~10.5", just big enough to fit a mITX mobo inside the diameter.

Here's the hardware I will be using:

Asrock H77M-ITX
i5-3570
2x4gb Corsair 1600mhz
Intel X-25M 80gb SSD
150W picoPSU
 

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The Fabricat0r
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5,933 Posts
Discussion Starter #2
Obligatory materials shot.

BM-003.jpg

Making the outer shell comes first, starting with a 1/8" round-over using a router.

BM-004.jpg

BM-005.jpg

Milling an opening (to be explained later) with my new-ish toy.

BM-006.jpg

You like my budget DRO
biggrin.gif
.

Using a 3/16" ball mill I started cutting the groves.

BM-007.jpg

10 down, 104 to go
doh.gif
. I'd kill for a cnc router. The groves will make it much easier to form the shell and I think will look good.

I went ahead and did a brushed finish just in case anodizing can be fit into the budget. If not, it'll get some flat black paint eventually.

That's all for today. Thanks for reading!
 

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Whao! Unique shape for a casemod.. Circles are hard.... :L So the way the casemod seems to look, are both sides curved hubs or just 1 side? Kinda reminds me of Spaceballs except for the chrome finish, Subbed!
 

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The Fabricat0r
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5,933 Posts
Discussion Starter #6
Quote:
Originally Posted by FNG-Protogenic View Post

Whao! Unique shape for a casemod.. Circles are hard.... :L So the way the casemod seems to look, are both sides curved hubs or just 1 side? Kinda reminds me of Spaceballs except for the chrome finish, Subbed!
Both sides will be the domed hubcaps.

I'd love to give a decent update on my progress, but after three hours I'm still far from done milling the reliefs.

BM-008.jpg

It'll probably be three more hours...
redface.gif
 

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Oh i see, yeah it really pains to not have a CNC mill.. Luckily I live near a pretty industrial part of Texas and can get my stuff sent in and done quick.. However I doubt I have the will to go do something as complicated as this. :/
 

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The Fabricat0r
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Discussion Starter #10

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The Fabricat0r
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5,933 Posts
Discussion Starter #11
I made some wood blocks to do some fine tuning with the help of a mini sledge.

http://picturepush.com/public/13492307

What I haven't shown is that I messed up on one of the grooves and it ended up being ~0.025" too deep. This made it a weak point and I had trouble with it bending more readily than the others which didn't end well.

http://picturepush.com/public/13492308

http://picturepush.com/public/13492309

mad.gif
Time to make a new one.

To make the grooves in the shell I used some two flute HSS mills. To makes things go a bit faster I'm going to order some four flute coated bits and try it again. Because of the small diameter I think I can move up to four flutes and not push my mill too much. I figured something would happen so I bought enough material to make a second shell. The next one should at least be a little easier to make
redface.gif
 

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The Fabricat0r
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Discussion Starter #13
I've been experimenting with annealing and it seems to make a difference. I took the broken off piece and heated it with a propane torch. Google taught me that if you mark the backside with a permanent marker, it will fade when you reach the correct temp for annealing. Once it cooled it did seem a good bit easier to bend. Mind you, it still wasn't very easy but I think I will try it after I machine the next piece. Strength isn't a huge issue so hopefully I can get by without tempering it when I'm done.
 

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The Fabricat0r
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Discussion Starter #14
To redeem myself from yesterdays complete failure, I started work on the uprights for the base. Using some 1"x2.5" flat bar, I ended up with this...

http://picturepush.com/public/13497119

http://picturepush.com/public/13497120

http://picturepush.com/public/13497121

http://picturepush.com/public/13497122

http://picturepush.com/public/13497123

http://picturepush.com/public/13497124

http://picturepush.com/public/13497125

Quite a bit to go with them, but I'm pleased. I also ordered more ball nose bits, should be here soon so I can get back to the shell.

Thanks for looking!
 

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The Fabricat0r
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Discussion Starter #17
Good news! I'm finally back to where I was two weeks ago.

http://picturepush.com/public/13553828

http://picturepush.com/public/13553829

http://picturepush.com/public/13553830

http://picturepush.com/public/13553831

http://picturepush.com/public/13553832

There's still a bit of a flat spot I only noticed just now looking at the pics. I also need to sand the inside and smooth out all those little bends.

But this one came out almost perfect and it only took three attempts
doh.gif
. The annealing helped a ton, you can still see the faded permanent marker I used as a temp indicator. Hopefully I'll have some more updates soon!
 

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Definitely in for this... wish I had a mill.
 
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