electricshoe

I have 3 computers, possibly 4 soon. I built mini plexiglass cases for two of them (See picture later) Nothing fancy, just a plexiglass box with a computer inside it. And my main pc is in a crappy acrlyic case I bought for 45$. You don't get to see a picture of it, I'm sorry. People who have never seen an acrylic case before think its cool but the cables are horrible and its just really gaudy.

For this project I essentially want to assimilate all my computers into a single sleek and sexy workstation, and have them all accessible through a pair of kvm switches (dual monitors). Everything required to run the workstation will be built into the case (2 KVM's, A mechanical USB switch, A network switch and a power strip). To fulfill the title, I am going for a very low profile look. I will be putting a window in it with some decent red lighting to accent the stuff inside. The paint scheme will be pure flat black with most of the inside aluminum staying its normal finish.

The first problem was getting everything to fit. I have a bit of experience working with Aluminum, but more construction oriented stuff. Like running channel and angle, not much with cutting sheet metal. So I started a design based around what I knew I could build. I wanted the most rugged yet simple design possible. Essentially I am looking to solve all my workstation worries for at least 5-10 years with a solid piece of hardware.

After a couple weeks of tweaking in 3d studio with a scale replica I arrived at this design:




The case is big, but its not humongous. The final dimensions are 24" x 12.5" x 24". All the grid square items are the Aluminum parts that I ordered today (6/30), and of course, each square is 1 square inch.

Essentially the framework inside is a series of extrusion (square and rectangular tubing), angle to support the mobo and psu trays (PSU's get a tray so i can get to the CD's and HDD's easily), and 4" flat bar to support the drives. The majority of the casework is going to be screwed together directly or with 90 degree angle pieces. I ordered in little 1" length of rod to fill the top and bottom of the extrusions so I can easily anchor the top and bottom of the case. More on this when the metal actually arrives.

I bought the aluminum from discountsteel.com, seems like its a really great site. Hopefully I won't have to do too much sanding. Here's a list of what I ordered for those of you interested in aluminum pricing.

Product	Qty	Weight	Price
Aluminum Square Tube 1-1/4" x 1-1/4" x 1/8" -- Length: 24"	2	2.64 lb.	$ 17.84
5052 Aluminum Sheet .080 -- 24" x 24"	2	8.96 lb.	$ 41.36
5052 Aluminum Sheet .125 -- 11.25" x 7.875"	1	1.07 lb.	$ 8.74
Aluminum Equal Leg Structural Angle 3/4" x 3/4" x 1/8" -- Length: 10"	8	1.36 lb.	$ 14.67
Aluminum Rectangular Tube 1" x 1/2" x 1/8" -- Length: 24"	1	0.72 lb.	$ 6.04
Aluminum Square Tube 3/4" x 3/4" x 1/8" -- Length: 17.25"	1	0.51 lb.	$ 4.57
Aluminum Equal Leg Structural Angle 3/4" x 3/4" x 1/8" -- Length: 5.75"	8	0.80 lb.	$ 12.00
Aluminum Flat Bar 3/16" x 4" -- Length: 9.75"	1	0.73 lb.	$ 4.67
5052 Aluminum Sheet .080 -- 5.75" x 6.75"	4	1.32 lb.	$ 24.57
5052 Aluminum Sheet .125 -- 10" x 13.75"	4	6.80 lb.	$ 43.82
Aluminum Square Tube 3/4" x 3/4" x 1/8" -- Length: 24"	5	3.60 lb.	$ 30.20
Aluminum Flat Bar 3/16" x 4" -- Length: 2"	1	0.15 lb.	$ 1.73
5052 Aluminum Sheet .080 -- 24" x 12.5"	4	9.72 lb.	$ 53.97
Aluminum Square Bar 1" -- Length: 1"	4	0.40 lb.	$ 5.97
Aluminum Square Bar 1/2" -- Length: 1"	12	0.24 lb.	$ 14.03
Aluminum Flat Bar 3/16" x 4" -- Length: 11.25"	1	0.81 lb.	$ 5.03
Aluminum Flat Bar 3/16" x 4" -- Length: 21"	1	1.54 lb.	$ 8.70
Aluminum Flat Bar 1/8" x 3" -- Length: 11.25"	1	0.40 lb.	$ 3.42
Aluminum Flat Bar 1/4" x 3/4" -- Length: 1"	2	0.04 lb.	$ 2.33

They're telling me that this is 41.81 lbs of aluminum. So add 50$ for shipping and you're looking at about 350$ worth of aluminum. It's a good price, it may seem like a lot of money to drop on something like this, but I am really counting on this lasting a while. It will be a very heavy duty case with very simplistic pieces, which will be really helpful should I ever have to replace or reinforce something.

.08" aluminum is a little bit thicker (by about .008") than the 2mm aluminum used in most cases. This should ensure good structural stability.

I'm keeping the cuts as simple as possible. I only have planned 10 80mm holes for fans (2 on each mobo, and 2 on the HDD's). A cut for the CD ROM drives, a cut for the top so i can fit a little door to access the backs of the kvm's while still keeping them covered, and a window for the side pictured in the model.

I've already received or had most of the stuff that I will be using in this mod:



The two computers at the top are the previously mentioned custom plexi boxes I made. A lot of these things are replacement parts for some stuff that needs replacing. Such as the Artic Cooling Silent Heatsinks, the CD/DVD ROM's and the Rosewill Powersupply. You can also see the KVM's and their cables, and many many other cables that are going into this box. Also I have bought some of the hardware for the actual case construction, mainly the velcro for mounting some of the devices, some hinges so I can attach the sides (each side is going to be able to swing open), and the aluminum fan filters.

There's still a few things I have to order in. I'd like some input from you folks as well.

For the limited amount of nonholesaw cutting I have to do would I be able to get away with a nibber or may a really cheap dremel (recommend one)

Also if anyone wants to recommend where I can get a good deal on some really short self tapping and just plain really short metal screws (Same thread as the self tappers hopefully!)

And if you want to know more or have any criticisms/inputs I'd be glad to read them!

Things I still need to get:

A nibber or a dremel (Based on your recommendations)
3" HoleSaw
Cable Sleeving Stuff
Lighting Stuff
Counter Syncs
Screws & Angle Braces

P.S. - I am spending my summer on Nantucket (An island in MA). Everything is really expensive here! Which is why I am asking for help with screws and stuff. I'll be doing my own research, but a good lead is always useful.

s1ugh34d

Wow that is gonna get hot, you may want to getwatercooler, personally i think it would be best, even then its gonna be hot with all the HDDs and CD-roms as i type this i feel input is being typed up by others

First the 80mm fans for the motherboards, are you gonna have them blowing ontothe back or front side?

Second, how loud do you care?, cause there are some nice cheap deltas and sunnons, theat are loud but effecient

Third, The Wires where will they be going, will there be a hole for all the VGA cords and PSU cords?

Fourth, where is this gonna sit,on the floor, and or tabletop desk?

Fifth the self tapping screws i dunno about, but i do know your best bet would be rivits, which dragonmods has some nice assortment of colored ones, in bulk and if you PM twizted, or lokie, i think you can get a custom big order in?

Okay thats all i can think of as of right now, and by the way


Welcome To PCApex


you'll never want to leave again, pull up a chair and enjoy

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electricshoe

Some things I should have mentioned but didn't

All the mobos will be facing towards the camera in the picture above. Their cables will run to the kvm switch in nice sidesplit sleeving, im getting a big roll of some nice stuff. everything will dock into the kvm area in the front. I'm waiting on the actual construction to figure out exactly how everything will be, but it will be neat.

the 4 psu's will run down and over to the powerstrip, along with the network switch and one of the kvm's (the other doesn't require power)

This fella is going on the floor (notice the wheels in the picture)

So all I will have is cables going into the case, and one cable coming out (the power strip). The PC's I have aren't top performance and don't run very hot. with 8 fans blowing on the mobos plus the 2 in front the airflow should be good enough. Also the case being completely aluminum should help out. This is something I'm waiting to see, if it really is a problem I'll get some 120mm in. Watercooling isn't an option for me, especially since I would have no where to put it in the case (And I don't want to pay even more to get it)

DickNervous

First, welcome to PC Apex. I think you will find that the folks here are knowledgeable and willing to help.

Next, this is an ambitious project for sure, and I know that if I didn't switch hardware so often i would consider doing it, but it is simply not feasible for me. But I agree s1ug, it is going to run hot, very hot. There is not nearly enough ventilation in that thing for this to work. I have less hardware and more fans in all of my cases, even the water cooled ones. So here are a few suggestions...

Cables/Positioning
-- I think you are going to have some problems with that design with the cables. Particularly the PSU cables. Unless you are willing to re-wire them all I think you will find that they will fall short if you are trying to keep the mobo-cd-hdd connected to one PSU, if you are not then you should be okay. Though if you do not do that then you will need to have all four systems powered up whenever you want to use any of them.

-- If you want each unit to operate independently, then you will probably need to lengthen some of the power cables for the HDD and CD drives.

Heat
-- First, forget about 80mm fans, get 120s. They move more air at slower (quieter) speeds and take up less space per cfm.

-- I am assuming that the mobos will be laying flat, as if on shelves. If so then you will want airflow going across each board. Since the front of the case will be blocked with PSUs and drives, that means a cross flow, side to side. And that means 4 120mm fans on each side, at least, blowing air across each board.

-- You should cut the panel behind the PSUs, I am assuming that they will be enclosed in the case as well, and use some modders mesh to help ventilate the heat from them. They will generate way too much heat to keep them enclosed insode the case.

-- Blowholes up top, make some.

General
-- Get some holesaws to cut the fan holes, you will need it.
-- Either buy a dremel or get yourself some files to smooth out the cuts
-- Get some fan controllers


If you want to think about water cooling it, you could mount multiple rads on the back of the case and run either 4 loops, one for each machine, or, you could even run 2 loops with 2 machines on each assuming you get a big enough rad and multiple pumps per loop. This would solve a good deal of the heat issues, but you would probably still need alot of fans.

Finally, IOGear makes a pretty nice dual-video KVM that also does audio and a USB device. I say pretty nice cause it does not have an on-screen display. I have it and it's okay. You could replace the two KVMs with that, but since you have them that might not be an option.

That's it for now. Good Luck!

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IcEMage

Quote: P.S. - I am spending my summer on Nantucket (An island in MA). Everything is really expensive here! Which is why I am asking for help with screws and stuff. I'll be doing my own research, but a good lead is always useful.

......There once was a modder from Nantucket, who...........(guess I should not finish that one)

Welcome to PCApex!!!111!!!11!

I look forward to seeing your work, good luck

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DickNervous

screws.. right. http://boltdepot.com

I ordered a bunch of stuff from them a year or so ago. Good prices and wide selection. And they are in MA.

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Bouve124

I really like your idea. If it were me I would keep it super simple and not bother putting any kind of doors/covers on this bad boy. That way heat really shouldn't be an issue. I mean all the fans on the mobo's will be able to pull fress air from the room. And if you wanna be safe then maybe mount 2 120mm fans at each mobo to blow some air across them. (someone please correct me if this wouldn't be sufficent cooling? for an open air setup)

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beachbum86

Welcome to PCA!!

Your project spiked my interest so I thought I'de drop in. I'm looking foward to how the finished product Looks.

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electricshoe

Heya everybody, thanks for the welcome.

The original design had 120mm, but I discovered a box of 80mm fans and at the time I was living in denial cause I didn't wanna spend any money. But the other half of my paycheck clears on wednesday(7/5) and thats gonna make me a happy man. So with that I'm gonna order in screws and a bunch of double ball bearing 120mm. Zipzoomfly sells them by the box. Im gonna keep the 2 80mm on the hdd and probably move another 4 80mm up front to blow on each psu.

I'm currently living in a 250 year old house that has a serious dust problem. My current computer completely seized up with dust and started randomly shutting off. I'm not too hip on going completely open air but I am contemplating cutting some holes for mesh, I was going to do a window, but for what I'm going for the mesh may look better.

I'm gonna rework the design when I get home from work. I'll also post all the side cuts and a couple different angles of the model. expect that in about 12 hours!

Also the reason for dual kvm's is that I want to be able to target each monitor to a seperate machine. The big one handles my main input devices and main monitor. The second one handles the second monitor, the speakers, and a mouse. And then there's the usb switch which will handle my devices, everytime ive used a usb kvm I've never gotten good results, and you can get an awesome 4 port mechanical switcher from AMC for like 6$ on newegg.com.

Monsignor Funkibut

I'm a fan of having everything in one place nice and neat.

But here's something to think on

Dell just delivered me a 6850 four-proc server with rails - more or less the same amount of stuff as you got.

Final shipping weight - 157 POUNDS! The box didn't even have handles - it had wood supports on the bottom for a forklift.

Maybe you best drop all your goodies on a scale and figure out if this thing will even be movable when all is said and done. Or plan on casters?

-MF

P.S. Server gone to customer already; I didn't get it to fold

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electricshoe

New Cooling Solution:



I sucked up my pride and bought some 120mm plus some aluminum filters to go with them. I also ordered in a 2' x 2' sheet of 1/8" perforated aluminum sheet. From that I'm going to cut a window for the opposing side and a piece for the front for the PSU's.

That way air will flow through the fans and then out the other side of the case, giving me a pretty open air system but not letting it be too open for dust.

I mentioned before that the cpu's arent that top notch, and just so you fellas dont keep suggesting water cooling I'll tell ya their specs:

AMD 64 3200+ / 1.5 gigs ddr ram / geforce 6800 / 2 7200 hdd / 2 cd/dvd
P4 3.0 ghz / 512 mb ram / radeon 9500 / 1 3600 hdd / 1 cd/dvd
1.8 Ghz Celeron / 512 mb ram / radeon 9250 / 1 3600 hdd / 1 cd/dvd

No water cooling for celerons, in fact both of the lower pc's were running great in their little plexi boxes with no fans at all. Eventually I will try to get 4 good computers into this box, but that is for a later time where I am also rich.

Im not too worried about weight, it should be ~100 lbs, but I'm a strong young man and I can move heavy things around.

Still browsing casually for some holesaws, screws, and paint (self etching)

I'll update again sometime within the next day with the panel cuts and the cabling solution, I've got a pretty strong idea that im playing with at the moment. This may work out pretty well.

Keep the suggestions coming, Just don't suggest water cooling please

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Paintball & Modding

Hey Man Like the design. I just got into this and Iwas wondering what program r u using for your designs????

jofultner

Alright, A multi setup Tech Station.I am not sure why.But then again why not,lol.Jo

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DickNervous

I think that overall design will work much better for you in the heat department.

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electricshoe

Paintball - I'm just using 3d studio, but for more mechanical stuff you should def go with AutoCAD or something more vector based.

Jo - My reasoning is that I don't want to have to build or create another case for at least the next 5 years of my life, cause if I don't have to spend any more money on casing I can get a better computer

electricshoe

Just a quick update:

I've mainly been ordering in parts, waiting on my metal to go in, this will probably be the last post I make until my metal arrives. Then this log will start moving with some real work getting done.

I worked out my angling(structural stability) and some of my cable flow solutions:



Essentially the cables for each Mobo are going to be anchored in side sleeving to the bottom brackets(not the trays) for the mobo above it, with the cables exiting above their ports. cables running out will run up to the sleeving and the over and into a seperate sleeve that runs between the cd and hdd. I'm going to test all this flow pattern out when the station is done, and then order the sleeving in that I need.

I also worked out most of the places I'm gonna stick bracket angle, note that in the picture they are not to scale and meant for representation only. I bought about 65 brackets today of different sizes, plus a pop rivet gun. I'm ordering rivets from the internet so i can get some good steel ones aleady painted black.

Essentially I've decided to run the pop rivets wherever the metal is too thin for screws. I'll be using screws to anchor the sheet to the main vertical supports and the angles to the supports. But I'll be using rivots to anchor the angles to the sheet. At the moment I'm depending on the strength of the .08" aluminum to provide a solid cross brace (Hypothetically it should) but if there seems to be a problem with the frame i'll be cross bracing it.

The mobo and PSU trays will be another good source of crossbracing, each one is gonna be attached with 4 thumbscrews at each corner (holes evenly spaced in the angle and the actual tray) that way they can all be anchored and removed by hand.

I also ordered in a 7800gs and a 250gig 7200 sata (should give me a big performance boost over my ata133's), also got a long sata cable for it. So until my metal shows up I'm gonna be cloning harddrives down so I can get the 250 running in this box along with my 160 gig storage, then move my 120 gig down to the p4 and clone his 40 gig onto it, and then change the 40 gig into a backup for my workspace (Thats gonna be fun).

One of the main points of this is so I can run unreal3 really well on my mainbox so I can be editing in engine while I run 3d, photoshop, and zbrush across the other boxes so I can do work in more real time without bogging my computer down with 3-4 memory intensive programs.

I've got a lot of parts coming in now, I just have to order the holesaws, the screws/rivets, some files, and the sleeving (but that can wait)

in the interim if anyone wants to leave any suggestions feel free, work will start soon as the metal shows up.

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MasterP

HOW THE HECK DID I MISS THIS????!!!!????
That's a killer project you've got there!
With the 120mm fans, you'll be sweet with the cooling

Great to see the level of planning you've gone to for this - I'm looking forwardto seeing the construction begin

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THRASHER2

Quote: Originally Posted by electricshoe