Project; Mark1

[Mark_Hardware]

You've all heard about it, and now it's here!


http://www.nzxt.com/forum/picture.php?albumid=17&pictureid=39


Sponsored in part by
NZXT

I will be bringing this log up-to-date over the next few days, so there will be several big updates.
This is my first mod, and consequently my first worklog. I will try to keep my story congruent and cohesive, as I don't always work in the most organized fashion. I tend to work on several things at once.
The case I'm using is the NZXT Lexa Blackline, with the red lights. It's a very nice looking case even by it's self. Here's some of the hardware I will be using;
eVGA 790i ftw digital motherboard,
Intel QX9770,
OCZ 4GB DDR3 1800 PC3 14400 RAM,
Tagan BZ 1100w psu,
eVGA GTX285 ftw graphics card,
Koolance Exos 2.5 watercooling system, with a Swiftech Apogee GTZ cpu block,
Hauppage winTV HVR-2250 TV card,
Western Digital Velociraptor 300GB 10K rpm HDD,
(5) WD 2TB HDDs,
(2) LG GGW-H20L bluray drives,
Antec Multi-Station Premier,
Fan controller, and sound card have not been decided yet.

Ok, a few generic before shots;
http://img291.imageshack.us/img291/8484/1114603808.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1) at 2009-06-15
http://img291.imageshack.us/img291/1755/1114603806.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1) at 2009-06-15
http://img230.imageshack.us/img230/7048/1114603802.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1) at 2009-06-15

Sorry, I forgot to take the before shots.

[Mark_Hardware]

OK so I have to apologize, the first few steps are not that well documented. You see, this mod came about in steps. When I got the case, I didn't even have any plans to mod it! Then I started getting ideas. First was a way to hide wires, with some simple sheet metal next to the mobo. Also, I was going to build a rack out of 1/2" square tubing for the Koolance to sit on. Then I ran into a bit of a problem. You see, the Imon is a dual bay device, plus two disc drives, plus a fan controller... Well that is more than the supplied 5 drive bays. So, the idea changed a little, to add a drive bay into the rack. But then I needed a way to cover it. And after days and days of trying to figure something out, I came accross a material that I knew would work.
http://img208.imageshack.us/img208/3017/261j.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-18
About this time, The design changed a little bit. Grew, you could say. I decided to use these panels to encase a metal frame, and on top of that would be a smaller case that will house the imon and perhaps a few other things. I refer to this as the minicase.
OK, a few hardware shots, goodies that the ups man brought :)
http://img145.imageshack.us/img145/1540/140ixm.jpg (http://img145.imageshack.us/i/140ixm.jpg/)
http://img413.imageshack.us/img413/5126/1000175a.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-15
http://img413.imageshack.us/img413/4254/1000173.jpg
By Hardware_Mark1 (http://profile.imageshack.us/user/Hardware_Mark1) at 2009-06-15
http://img413.imageshack.us/img413/5236/1000174.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-15
And the first chops,
http://img218.imageshack.us/img218/4530/038e.jpg (http://img218.imageshack.us/i/038e.jpg/)
I also cut off the metal that was rolled over along the edge of the drive bays.
http://img524.imageshack.us/img524/5998/1000051l.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-15
That'll be all for today, have to go to work. I apologize if things are a bit unclear, I promise it gets better!!!

[Mark_Hardware]

Hey I did get a little bit of a before shot.
http://img145.imageshack.us/img145/1540/140ixm.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-18

http://img221.imageshack.us/img221/5245/1781401224.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1) at 2009-06-19
OK, first, the blue lights have to go.

http://img221.imageshack.us/img221/9382/1000605.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-19
Thats better.

Originally, the idea was to use sheet metal, flush with the motherboard, to hide the wires. Well it became evident fairly quickly that that wasn't going to work. So I decided to make it stand out more, as well as overhang the mobo to hide the power connector and sata connectors. Also, I decided to make it go over the graphics card, instead of underneath it. This will hide the power wires to the card. I call this the "wire channel." Sounds confusing, you'll see what I mean.
Other ideas I had from the beginning was to use sheet metal to make a psu cover, and drive bay cover.
Instead of sheet metal I am going to use these panels.
http://img211.imageshack.us/img211/7559/1000078b.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-14
http://img265.imageshack.us/img265/5239/1000075j.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-14


This is why I cut the metal off the side of the drive bays.
This is was the first attempt;
http://img209.imageshack.us/img209/930/1000085.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-14
I don't like it. I recut it, using straighter lines. Also, I wanted to be able to see the lights on the front of the psu, without seeing the wires. I came up with the idea of of putting holes in that area, effectively creating a grate, sorta.
http://img209.imageshack.us/img209/4058/1000189e.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-14
Then I took a micro file and filed all the holes square, as you see I started there.
Here is the final result of that.
http://img221.imageshack.us/img221/2520/1000622.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-19

I also started cutting a piece for the bottom.
Warranties voided so far; 2.

[Mark_Hardware]

OK, so once again, I started on the side panel. This is the last one of these I am cutting, dangit. Here is the third, and final revision. I am still going to cut something in the panel to let som light through, but I haven't decided what yet. And, until I know for sure, I'm not doing any cutting! I also cut a smaller piece for the 3.5" bays. Here you see those two pieces, plus, you can see where I cut out the material on the backside of the HDD cage.
http://img265.imageshack.us/img265/7863/1000626.jpg


Here is a shot of the piece cut to cover the bottom of the case.
http://img266.imageshack.us/img266/2496/1000625.jpg (http://img266.imageshack.us/i/1000625.jpg/)
The square hole is for the fan on the bottom. The edge on the top that is uneven will be under the motherboard.
Speaking of the bottom.... I am working on building a 'skirt' to go around the bottom.
Here are the bolts I am using. I love these bolts! I believe they are called "elevator bolts."
http://img211.imageshack.us/img211/5422/1000632.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-19

I started out using 1/2" square tubing. Eventually, I figured that 1" would be much easier to work with. Yeah, it will add some weight, But oh well, this baby is gonna be hefty by the time I'm done anyway.
http://img142.imageshack.us/img142/4303/1000637.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-20

I had been trying to figure out something to use to fill up some space, as well as add a little something extra. I have this skull,
http://img142.imageshack.us/img142/9769/s7366.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1) at 2009-06-20
that I want to incorporate into the case. I thought about several different avenues, then I saw this, and I knew that was it.
http://img223.imageshack.us/img223/766/1000627g.jpg
By Hardware_Mark1 (http://profile.imageshack.us/user/Hardware_Mark1) at 2009-06-19
It's a heatsink, from the same place I got the panels. I am going to cut and file away a lot of the material in between the fins. The idea is to see the skull, but only kinda. I want the reaction not to be, "Oh, another skull," instead, "What's that? Oh wow"

[Mark_Hardware]

Here is another picture of the HDD cage.
http://img142.imageshack.us/img142/7251/1000635.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-20
I did this so I can flip the hard drives around, so the cables will be on the backside, instead of on the window side.
I will have to mod the HD rails so they line up right, but I will do that later.
http://img341.imageshack.us/img341/7310/1000657.jpg

Also, I am thinking of building some kind of a box onto the back, to hide the hundred or so wires that go to the back of the computer. Haven't quite decided exactly how I want that to look. Something like this....
http://img257.imageshack.us/img257/1695/056o.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-18
http://img151.imageshack.us/img151/6208/057c.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-18
Now you can start to see a little bit of a bigger picture. eh?
In that pic, you can see the rivets I had originally used to mount the panels to the case. I pitched that idea with the newer panel, in favor of a method resulting in a cleaner finish.

OK, so some progess on the skirt. Here you will see why I switched to the 1" tube.
http://img504.imageshack.us/img504/9784/5302009072.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-20
I can screw the bolts right into the bars! And this makes mounting the skirt to the case a snap.
http://img155.imageshack.us/img155/8830/1000650.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-21
http://img87.imageshack.us/img87/3448/1000651.jpg

Also, here is part of that heatsink I showed you earlier. I am so happy with the way it turned out!
http://img151.imageshack.us/img151/9506/1000643a.jpg

I still haven't decided how I am going to style the front part though. The back, however, is pretty simple. I took the back leg, which also held on the curved piece of plastic that goes on the back of the case. Well, the leg won't work with the skirt, but I need to hold on the rear piece.
http://img413.imageshack.us/img413/2987/1000660.jpg
http://img141.imageshack.us/img141/4040/1000658p.jpg
http://img141.imageshack.us/img141/9149/1000659e.jpg

Easy fix, just cut off the superfluous plastic!
http://img151.imageshack.us/img151/6291/049cmm.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-18


Here is a couple more pictures showing some progress
http://img155.imageshack.us/img155/5554/079t.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-18
http://img155.imageshack.us/img155/6/080p.jpg
By hardware_mark1 (http://profile.imageshack.us/user/hardware_mark1), shot with KODAK Z1285 ZOOM DIGITAL CAMERA (http://profile.imageshack.us/camerabuy.php?model=KODAK+Z1285+ZOOM+DIGITAL+CAMER A&make=EASTMAN+KODAK+COMPANY) at 2009-06-18

I made a psu cover, as well. Nothing too fancy...
http://img151.imageshack.us/img151/9154/1000645a.jpg
The metal tabs will let me screw it onto the back of the case.
Next update, I start building up!

[Mark_Hardware]

Now I cast my eyes upward.
Originally, the idea was to use the 1/2" square tubing to build a frame. Again, I pitched that in favor of 1" tube. So I made these two simple square frames.
http://img93.imageshack.us/img93/4241/5302009122.jpg
JB weld, plus angle irons. Should be sturdy. I wish they could be welded, but I don't have any means to get that done. The piece of panelling on the side is just to get it square.
http://img229.imageshack.us/img229/6838/1000665.jpg

More of the elevator bolts will mount them to the case. These are especially useful where the rear frame is, since it's right above the psu, and there is limited clearance.
I also cut out the fan grill on the top of the case. I am going to put a piece of 3" pvc pipe here, as a "ventilation shaft."
http://img261.imageshack.us/img261/2272/1000666g.jpg
http://img229.imageshack.us/img229/3808/1000668.jpg

This whole area will be enclosed with panelling, with the "vent" on the left side. This will house the skull I showed you earlier.
The right side, nothing too complicated.
http://img208.imageshack.us/img208/1120/1000669f.jpg

The back will be a simple panel.
Another simple panel will close off the area where the skull sits. I had a picture of those panels, but they didn't turn out very good.
Speaking of the skull, I gave it some life.
My new hard drive activity lights!
http://img208.imageshack.us/img208/2167/1000640w.jpg

[Mark_Hardware]

Yay delivery!
http://img141.imageshack.us/img141/8121/1000681p.jpg

Hmm deja vu....
http://img524.imageshack.us/img524/4337/139mao.jpg

Now why, oh why would I be showing pictures of a new case now? Because it's Lexa case number 2!!!
I know it doesn't seem to make sense to buy a whole 'nother case, but I have several reasons for doing this. 1, it will save me a lot of work if I use pre-existing drive cage, as opposed to building my own. 2, in an effort to help, my desk was cleaned for me, resulting in most of the screws that came with the case getting lost, or mixed in with all my other similiar hardware, thus becoming hopelessly confused.
So basically what I am going to do is take this case, and shrink it down to about half size. I need the two drive bays for my Imon controller. I also decided to give myself one more extra 5.25" bay, just in case. I also went ahead and put in a cage for one HDD, just for the heck of it.
Sooo, some quality time with ye olde power drill, and it's presto, yet another warranty voided. This one within five minutes of taking delivery!!
And here we go, a nice pile o' parts.
http://img229.imageshack.us/img229/7594/142.jpg

Now I'll keep the top and bottom intact, obviously. Also, I am keeping the mobo tray and back panel intact. I won't be using it in this build.
Cut the right side panel.
http://img141.imageshack.us/img141/4056/1000682.jpg

OK, so my big plan for this part; I am calling this the minicase. The idea here is to make it look like the regular case, just, uh, smaller.

So I chopped the the 5.25" cage down to size. I chopped down the corresponding front panel, as well as thee HDD cage, for one hard drive. Here are those pieces mocked up together.
http://img229.imageshack.us/img229/3783/149j.jpg
Made a psuedo rear panel.
http://img141.imageshack.us/img141/8994/1000680.jpg
http://img150.imageshack.us/img150/8930/1000679f.jpg

I actually am planning on putting a couple things in there like regular pci slots. One thing will be the video capture inputs that came with my Hauppauge TV card.
Of course I will have to lengthen the wires.
http://img150.imageshack.us/img150/1623/1000673.jpg
And now I leave you with this (teaser?) shot:
http://img526.imageshack.us/img526/8692/156f.jpg

[Mark_Hardware]

Alright, did some work on the minicase. Like I said, it's supposed to just be a smaller version of the case.
JB Welded the pieces of the drive bays together. It looks like crap. I'm going to make sure as much of it is hidden as possible.
http://img44.imageshack.us/img44/3792/1000690s.jpg
http://img229.imageshack.us/img229/3930/1000688.jpg
http://img44.imageshack.us/img44/520/1000689r.jpg

Riveted the cage to the front panel.
http://img141.imageshack.us/img141/522/1000687.jpg

Cut a new side panel.
http://img99.imageshack.us/img99/6042/1000700i.jpg

Now in the minicase, there are no 3.5" bays, so there is no "step down." So I cut the edge off, and kept the ridges, to replicate the edge of the other side panel.
http://img31.imageshack.us/img31/3895/1000709g.jpg
http://img31.imageshack.us/img31/7858/1000711.jpg
http://img189.imageshack.us/img189/2258/1000702i.jpg

http://img141.imageshack.us/img141/9589/1000713.jpg

Also cut a panel to "cover the psu" Obviously there is no psu in here, this is just to keep the look going.
http://img229.imageshack.us/img229/6748/1000716.jpg

And we have a problem. The fan is in the way.
http://img81.imageshack.us/img81/5861/1000718p.jpg

I don't want to put the panel in front of the fan, cause then you wouldn't even be able to see the fan. So, I'm going to redo the rear panel. That will have to wait until I get more sheet metal. I need to get a heavier gauge. I will remake it with fewer pci slots, I'm thinkin just 2. That will let me lower the fan, and I think it will help make it look more to scale.

Cut a bottom panel.
http://img141.imageshack.us/img141/4586/1000698.jpg
http://img141.imageshack.us/img141/8108/222oiv.jpg
lol I promise the smaller pvc pipe in the back lines up better with the hole. That was just a mockup. And of course the 3" is directly underneath that fan grill.

Installed a length of 1.5" pvc, to act as a conduit to run wires back and forth between the cases.
http://img526.imageshack.us/img526/5426/1000685b.jpg
http://img526.imageshack.us/img526/756/1000686h.jpg

I am going to have the Imon in the minicase, as well as the video capture device, one hard drive, and Idk what else. I am going to have some servo controlled parts, so I am thinking of mounting the servo controller to the right side, like a simulated motherboard.

Here we go, a couple of progress shots.....
http://img141.imageshack.us/img141/2271/1000697.jpg
http://img81.imageshack.us/img81/9676/1000696.jpg
http://img141.imageshack.us/img141/8535/1000695.jpg
http://img44.imageshack.us/img44/4611/182u.jpg
Maybe this will clear up some confusion


Confusing? I prefer 'Enigmatic'

[Mark_Hardware]

Alright, a couple smaller things...
As I got to looking at the HDD cage, I noticed that when it's full, the bottom hard drive won't really get any air from the fan in front. (yes, it will be full, eventually.) So, I decided to fix this by adding a fan on the bottom. 80mm fan fits right in there.
http://img401.imageshack.us/img401/37/1000762d.jpg
Drilled holes in the bottom panel of the case. Can you guess which one I did and which one is stock?
http://img145.imageshack.us/img145/6156/1000378.jpg
http://img33.imageshack.us/img33/7523/5302009086.jpg
Yeah looks like garbage. I'm just gonna take the 3" hole saw and use mesh. Even though that won't get seen, I know it's there....

Also, the door sans hinge is annoying. I'll fix that. I'll start by cutting off the rolled over metal.
http://img522.imageshack.us/img522/9644/232r.jpg
http://img406.imageshack.us/img406/4017/226h.jpg
http://img443.imageshack.us/img443/6162/236d.jpg

Jeezas that was a pain.
I cut off the corresponding rolled metal on the case. I don't seem to have a picture of that part right now....

I used a solid hinge, mainly because I knew that if I used a few smaller hinges, I wouldn't get them all lined up right and it would just piss me off.
http://img19.imageshack.us/img19/5489/1000759mkl.jpg
Cut a few areas in the hinge to get around rivets and such.

Good ol' JB Weld to the door.
http://img406.imageshack.us/img406/1808/1000760.jpg

Yeah, so the picture isn't all that great, cause I ahem kinda goofed. I used wax paper when I clamped the hinge to the door, to keep the clamps from getting glued to the door. Well, it wasn't wax paper like I thought, so the paper stuck to the door. Nice.
I will sand this all down, and if im not happy with how it looks, I'll just cover it in some bondo. Same with the half that's in the case. I have to figure out some way to cover that up, maybe another piece of that panelling, mebbe just simple sheet metal, idk yet.

I'll do the same for the minicase.

[Mark_Hardware]

So I finally decided what I am going to do with the front, or at least the part on the bottom.
http://img407.imageshack.us/img407/8681/1000728o.jpg
http://img155.imageshack.us/img155/7291/1000721.jpg

It's a large heatsink, this one with the edges and such still intact. I had to cut it down, it was a bit too wide. This left it asymmetrical. Dammit. Oh well, I will just cut off one fin, and maybe glue it back on in the center.
I cut the plastic so that it runs down into the fins. I will use JB Weld and bondo to make a smooth transition, and hopefully get it to look like one solid piece.
http://img301.imageshack.us/img301/1927/1000739y.jpg
http://img221.imageshack.us/img221/7480/1000745.jpg
http://img33.imageshack.us/img33/441/1000780d.jpg
http://img219.imageshack.us/img219/5266/1000781b.jpg
http://img155.imageshack.us/img155/9025/1000750.jpg

Nah, I'll just leave the middle like it is. I like that body line, and I think I want to keep it.
At the same time, I am having issues with the left side panel. I had it all together once, but then I found two things wrong with it, so I broke it apart and am redo-ing it, step by step. Here is an ugly picture showing the progress on that.
http://img12.imageshack.us/img12/5660/1000763k.jpg
http://img33.imageshack.us/img33/7386/1000765f.jpg

I am also notching out a space for the front audio header. I cut out the plastic surround from the factory location. http://img155.imageshack.us/img155/9083/1000758a.jpg
http://img518.imageshack.us/img518/7393/1000782.jpg

Yeah I screwed up. It got rubbed by the collet on the dremel. I'll have to sand that out.
Here is progress on that notch.
http://img518.imageshack.us/img518/461/1000776o.jpg
http://img301.imageshack.us/img301/6149/1000778.jpg
http://img170.imageshack.us/img170/124/1000772.jpg
http://img515.imageshack.us/img515/7721/1000773z.jpg
But my last cut off wheel broke, so I'll have to get more later. Happy 4th, for those it applies to!

[mostwantedbmw]

wow you are very quick. kinda reminds me of MnPctech, i cant wait to see the end result! :D

[Mark_Hardware]

lol I'm not that quick, I am just bringing it all up to date :p keep your eyes peeled, lots more comin!

[Mark_Hardware]

OK, a quick update today, not too much to report.
Got the front header area cut away.
http://img248.imageshack.us/img248/6491/1000847.jpg
http://img443.imageshack.us/img443/918/1000843.jpg

Let me tell you friends, that was the exact opposite of fun. No room to move a file, no room for any dremel attachments... Ugh

Still needs some finish filing though...

Next I need to cut down the fins a little bit so the plastic cover will fit and be flush with the front of the fins.
http://img339.imageshack.us/img339/3193/1000851i.jpg
http://img513.imageshack.us/img513/9042/1000853.jpg

Thats all for now, gotta go to work!

[Mark_Hardware]

OK, another small update. Just been working on this front header more. Got more of the filing done.
http://img265.imageshack.us/img265/2415/1000867g.jpg

Sits down in there nice now.

http://img146.imageshack.us/img146/7280/1000859.jpg
http://img406.imageshack.us/img406/2615/1000860.jpg

I am going to cut down the pcb a little so it doesn't hang over,

http://img80.imageshack.us/img80/4271/1000862.jpg

Been really busy, so haven't had time to do much.
This weekend I will drill a couple holes for wires and start filling in the gaps.

[Mark_Hardware]

Sooo.... Let's take a look at the material I'm using, as well as some of the methodology as it's evolved.
http://img528.imageshack.us/img528/4852/261w.jpg

Here is the source of the material.
http://img89.imageshack.us/img89/479/1000883b.jpg

They are data recorder boxes. "The little black boxes." On the end you'll see where the heatsinks come from.
http://img172.imageshack.us/img172/4338/1000882e.jpg

The boxes are made from some kind of aluminum (alloy?) cast, hard as hell (hardened?) and a nightmare to work with sometimes. So far I've ruined my (really nice) jigsaw, dulled three files, and gone through more jigsaw and sawzall blades than I can count.
Speaking of sawzalls... When I started, I didn't have a sawzall. See this lip?
http://img243.imageshack.us/img243/5197/1000879j.jpg

It's not possible to cut with a jigsaw. Solution? Drill a hundred holes then file down all the ridges.
http://img172.imageshack.us/img172/7585/1000049c.jpg
http://img140.imageshack.us/img140/5830/1000048i.jpg
http://img294.imageshack.us/img294/3303/1000047.jpg
http://img55.imageshack.us/img55/4599/1000046u.jpg

Sweet baby Jesus that did suck. Also it resulted in piles and piles of metal shavings, which my wife was just thrilled about.
http://img294.imageshack.us/img294/5319/1000155.jpg
http://img55.imageshack.us/img55/7355/1000054.jpg

I don't have a workshop, I live in a crummy little apartment, so I work in my living room. (in case you haven't figured that out by the backgrounds in my pictures lol) Something else my wife is thrilled about.
Here is the result of the drill/file method
http://img294.imageshack.us/img294/5885/1000881.jpg
http://img172.imageshack.us/img172/282/1000880.jpg

I am happy to report that I finally made the trip to my friendly neighborhood Harbour Freight and got a sawzall and a new jigsaw.
http://img140.imageshack.us/img140/9927/1000885.jpg
http://img217.imageshack.us/img217/6807/1000884x.jpg

Much better. Still, each cut is a pain, and I have to file and file and file..... Gawd I am sick of filing. I don't even want to use my filing cabinet anymore. filing.....

[Mark_Hardware]

Here we go, nother update.
Got the front piece glued together. This weekend I will be working on filling all the gaps. I cut down the pcb,
http://img140.imageshack.us/img140/3395/1000917e.jpg

Well crap. I cut it down to the point where I didn't need to cut the groove in the second fin. Oh well.
Anyway, I figure I won't be using the plastic piece I cut out. I will just make my own cover. Here is a test piece. This is not the final piece, but something to give me an idea of what to do. First, I apologize, I had a hard time getting good pictures.
http://img140.imageshack.us/img140/2533/1000905b.jpg
http://img440.imageshack.us/img440/853/1000908.jpg
http://img246.imageshack.us/img246/8302/1000911a.jpg

Here you can kinda see what I am going to be doing to match and blend that bodyline of the case.
http://img154.imageshack.us/img154/2877/1000914s.jpg
http://img528.imageshack.us/img528/4303/1000910r.jpg

Here is something that will boggle everybodies minds.

http://img133.imageshack.us/img133/1028/1000876.jpg

That's right, door. Permanently glued shut.

Made some cuts...
http://img140.imageshack.us/img140/9130/1000891.jpg
http://img528.imageshack.us/img528/3595/1000900k.jpg

and we have access again.

http://img246.imageshack.us/img246/8683/1000898.jpg
http://img246.imageshack.us/img246/9084/1000899i.jpg
http://img89.imageshack.us/img89/7029/1000895.jpg
http://img528.imageshack.us/img528/8885/1000894.jpg

Sanded down the edges, to clean it up a bit.
http://img154.imageshack.us/img154/5086/1000935b.jpg
http://img237.imageshack.us/img237/5066/1000938d.jpg
http://img219.imageshack.us/img219/8328/1000939i.jpg

The cover still fits nice.

http://img132.imageshack.us/img132/8736/1000941.jpg
http://img132.imageshack.us/img132/2119/1000943.jpg

[Mark_Hardware]

OK, so it has come to my attention (more than once) that people may feel a lack of direction in this build, hence a lack of enthusiasm.
I admit I did not undertake this project with a concrete plan. I had a general idea, a few things I wanted to do, then I let the inspiration come to me. I took an artistic approach to this whole project. Da Vinci reworked his ideas many times before realizing a final result. And just like Da Vinci, I have a few things I know for sure and hold to, and let the rest come to me as the pieces speak to me.
K enough art teacher speak.
I have a few ideas that I've had from the beginning, and that I know for sure that I am going to implement. Namely, Largely, the doors.
Ahh the doors. Something that can make or break a case. Or just plain break and screw the whole deal up. This case has a neat looking door. Sharp body line that I love, cool lighting....
Now how can I make it better. How can I make it, different.
You saw that I glued part of the door on, then cut part off
Here's the idea, presented in no-talent sketchup.

This is the front piece to the door.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_0956.jpg
The whole front of the case has these matching pieces with this beautiful finish.

I am going to cut that in half. I will mount a servo that will open the door as such,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_0960.jpg

then another servo, mounted on the inside of the door, will "slide" the door back, as so;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_0966.jpg

this of course will be mimicked on the other side. (and remember, that door will be cut in half)
There are three places this will occur.
On the mini-case, where the Imon holds it's place of honor,
Of course the main drive bay area,
and...

On this bottom section,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_0971.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_0970.jpg
Those are some progress shots showing the bondo work coming along.

Think armoire doors,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/armoiredoor.jpg

[Mark_Hardware]

OK ladies and germs, here we go....

Not much of an update today, but I promised I'd get something out this week.
This piece has been kicking my butt all week.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1057.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1044.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1045.jpg

Hopefully you can kinda see where I'm going with this. I have to sand down all the bondo in between all the fins, for one. The problem is, it's very difficult to do by hand. I used a dremel with this attachment,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1072.jpg

But that left a rough finish. Btw I know that's not the designed use for that attachment, but it actually worked really great for that. I still use it, but only to take the bondo down a little, not all the way.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1051.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1054.jpg

I have come up with a potential solution to this problem, a simple block of wood, sanded to the size to get in between the fins.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1086.jpg

Here's the other problem area.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1055.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1056.jpg

I am trying to get a smooth transition between the plastic cover for the front header, and the rest of the cover. This really is the area I am having the most trouble with. I can't quite figure out how to attain the look I'm going for.
I'm thinkin I will just take a break from this part and work on a different area for a while....

Here is the front of the minicase. The plastic there is cut off the front bezel from the second case.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1087.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1042.jpg

Here is the piece I am thinking I will attach here.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1075.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1073.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1074.jpg

I know it seems a bit odd, or backwards to attach the bottom piece here. My reasoning for that is twofold; one, I it will make the plastic level with the front of the Koolance unit. Two, it is longer, so it comes down to about where I want it. One other thing (ok so it's threefold) is this gap will be a great spot to mount this remote control reciever that came with my Hauppauge tv tuner.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1082.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1076.jpg

One other thing, got a surprise in the mail today, the data cable I ordered. It's a usb to serial cable. I have to give a quick shout out to bestlinknetware.com. I searched and searched for this cable, and I would find a 12" one for $13, but the wouldn't work. Then I would find a 6' cable for $30 plus. That wouldn't work either lol. Plus, they were all blue. Yeah, so, anyway..... But this site had this cable, in black, 40" long, and for 8 bucks. Oh hell yeah. And it got here really quick, I was surprised! [/schelling].
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1083.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1080.jpg

This cable is for my servo controller, when it comes on Monday.

So that's all for today. I was hoping to show some more definitive progress, sorry guys.

[Mark_Hardware]

Hello all again just a quick text update today....
So starts the beginning of my weekend today. Gonna run a few errands, including a trip to ye olde Harbour Freight as well the my freindly local neighborhood Home Depot for supplies.
Quick stop by the doctors office (always fun) then it's on to modding! Oh yes I plan on getting some serious work done this weekend. It's on like Donkey Kong.
Gonna do some (more) work to the front piece, as well as an idea I recently came up with, a place to stash my ipod.
I got my servo controller in the mail, and I only got one servo (lame) cause I'm perpetually broke these days.
But I plan on figuring out how to mount one of the servos for the doors, and hopefully get those going in the right direction.
We'll see!

[Mark_Hardware]

So just got back from running around... Got cleared for surgery (yay) and a trip to Harbour Freight resulted in a little more than just sawzall blades.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1140.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1141.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1143.jpg

Oh yeah. It's not huge or anything, but hey it's a friggin drill press heck yeah! I'm super excited I've wanted one for a long time. This will definitely come in handy!

[Mark_Hardware]

Update for today, and as usual, I didn't get as much done as I had hoped. But in my defense I had an excuse today. Car drama,
and some kid drama too.
Anyway, Been working on a special place for my ipod. A door, behind the vent, that will open and presto, docking station.
Here is the rough cut hole.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1144.jpg

And ipod for perspective.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1146.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1147.jpg

Filed smoooooth;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1150.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1151.jpg

This is the backside of the door. I am using 5/8" U channel for the ipod to slide in. Eventually I'll mount the connector in the bottom, too.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1183.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1184.jpg
(I realize I should have set it on the table, not on top of another panel, to avoid confusion. Oops)

Now, the putting a hinge on here is way trickier than I thought it would be. Hopefully you can get an idea why. Here it is closed;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1153.jpg

Here it is open;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1158.jpg

It lifts just a little in the back, so a straight hinge won't work. This kicked my butt all day trying to get something worked out. I tried making a hinge with a bar and lines cut in sheet metal, but it wasn't stable. So, I decided to try making an assemblage that would allow the door to slide straight out.

The concept;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1175-1.jpg

mocked up in place;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1176-1.jpg

and trashed;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1177-1.jpg

Sigh. Came up with a different solution. It won't be hidden, like I wanted, but if it works, then it's what I have to do. It's a simple as just flippng the hinge around, and making a notch for the barrel. Here it's done on a scrap piece for testing;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1179.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1180.jpg

Here it is mocked up, to give you an idea of what it will end up looking like...
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1181.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1182.jpg

Oh, and for anyone interested, I have still been working on that pesky front piece. I don't make it focal point for now though. I work on it when I feel like taking a break.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1186.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1192.jpg

[Mark_Hardware]

Quick update today, not much work done.
I decided to make a groove where the barrel of the hinge will rest, instead of cutting a notch. This will make it more discrete, cleaner, smoother.

Here is the hinge resting in it's new home,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1197.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1201.jpg

And getting glued.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1204.jpg

That's it. Tomorrow when the glue is dry we'll see how it fits/works.

[Mark_Hardware]

Here we go.
Been working on my ipod dock this week. I've been doing little bits before going to work. Little bits of progress that aren't worth posting about, but are time consuming nonetheless.
Here is the door, with the guide in place and sanded down a bit.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1255.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1256.jpg

Made a bracket to mount the servo;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1257.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1258.jpg
Ha didn't see that one comin, did ya!

Here it is all clamped up
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1259.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1260.jpg

Now the last step, glue on the piece for the armature mount.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1263.jpg
I did this last because I wanted to test out the servo first and determine the best postion for the mount.

Now I have to wait till tomorrow for the glue to dry (dammit) then do some sanding, and cult some felt to line that uchannel with, but other than that, the ipod door is done!

[Mark_Hardware]

Here is a short, crummy video of my ipod door in action

http://www.youtube.com/user/MarkHardwareOnline#p/a/u/0/amAl-GEv9c0

[mostwantedbmw]

crummy? that was good quality to me. i like it, seems sweet. youve inspired me to go and buy a cervo in the near future...

[Mark_Hardware]

well, it is in Hi-def lol.
and ty, tyvm :D

[mostwantedbmw]

:) whered you buy yours?

[Mark_Hardware]

http://www.lynxmotion.com

[mostwantedbmw]

40 bucks, not bad. ill hit up the link when i get my paycheck :D

[Mark_Hardware]

hehe. I have some more stuff to get from them.... I'll hit em up again....uh, someday :)

[cool_clint_15]

Its looking great so far, and I like the docking area for your ipod.

[Mark_Hardware]

Thanks!

Ok, not much today. I have been waiting over a week for this, and it finally came.
It's a 5" lcd screen for use with various gaming systems
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1313.jpg

Kind of a cool little deal, too. Also came with a base to attach it to, whatever, as well as a cable for use with xbox or playstations.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1314.jpg

But I'm not interested in all that! Here's what I want!
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1319.jpg

Hmm. Not quite what I was hoping for.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1321.jpg

Here is where the monitor is going.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1326.jpg

The backside;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1323.jpg

This is going to be a challenge. I'll keep you posted as I make progress on this.

[Mark_Hardware]

Nooooo tragedy strikes!!
My trusty Dremelike has officially taken a dump on me.
Here is what I was working on;

The damn cutoff wheel jammed, and it broke the flex attachment, and I guess it was just too much for my old rotary tool to handle. Damn you, hard *** aluminum! Damn you.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1346.jpg

Some progress,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1328.jpg

Cut out the hole. Now, bear in mind, I will have to eventually cut this hole larger, to accomodate the mechanics for the doors that will cover it.

I started grinding down the fins behind the screen, so it will sit down flush.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1343.jpg

Eventually I decided to just cut the fins off. The don't serve any purpose, and they won't be seen back there.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1331.jpg
Plus it's a little weight reduction. win-win.

Idk if I'll be able to get a new one today... Still have to work on my car (again). Can't really put that off much longer or I won't have power steering anymore.
So, after 6 years of trusty service, it's time to give my loyal tool a proper send off....

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1348.jpg
Good bye old friend.

Ohh yeah ps, I set my stuff up on the table while I went to the store, and when I looked at it, that would be a sweetass place for a monitor. Not many 3.5" bay devices to use, for the most part anyway. Just sharing an idea, mebbe someone can use it :up:
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1333.jpg

[Mark_Hardware]

Well, half assed update. I'm still not feeling all that great, but I wanted to try and get some work done. Unfortunately, things went from bad to worse.

I decided to go a different route for the screen. I need to have room for the hinge mechanics, so a flush mount won't work. I decided to cut out the whole area and recess it. Basically, it will kinda look like the main drive bay area. After a couple of ill advised, not carefully planned cuts, I have this;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1372.jpg

Not what I was going for. At all.

Soooo, I started cutting out what is now the bottom section, since the front piece is now two pieces. Sigh. Then this happened;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1375.jpg

Grreeeaaat. Sure that's what I was going for. Here is the line I was cutting along;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1374.jpg

The idea, like I said, is to cut out this whole area. It will be covered by doors.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1377.jpg

So that's it. yippee. Sorry, I started out in not that great of a mood, and it sure didn't get any better.

[Mark_Hardware]

So, made a little progress today. Turns out, that piece breaking made it easier to cut right. (See the focusing on the positive part there?) Here's those two pieces;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1381.jpg

Now, I have been puzzling over what material to use to build the new back and mount the screen. I didn't want to use sheet metal, I would rather use plastic, and a good plastic epoxy. Then it hit me, just use the casing the screen came in! So, trimmed it down a bit, and it will fit as such;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1386.jpg

Maybe that will provide a little clearer picture as to where I am going here, too. Now, of course it still needs more trimming, and I will fill the various holes so it looks like a solid piece, but it's perfect cause it's already ready for the screen to be mounted.

All this speak of the screen, I will sequay into bad news. Here is my screen;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1391.jpg

Yeah.... and that's all it does. So that sucks. Nothing like some bad news for a change. Hey, could be worse though.
Anyway, came across something the other day that finally struck me for use as mesh. I have been searching and searching, cause I just wasn't crazy about the usual suspects. Walking down the isle at My Friendly Local Neirbourhood Home Depot and my wife said, "Hey what about this?"
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1388.jpg

[Mark_Hardware]

An update! Not a huge one, though. I'm gonna keep working through the weekend, so hopefully some real progress will ensue.
Here is one thing I need to do, this part broke. Some jb weld to the rescue there.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1459.jpg

What I actually have done so far,
glued the piece for the monitor in place. Here I used a plastic epoxy instead of JB. I thought I would spice it up a bit lol.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1469.jpg

Then I cut it to the right length to match up to the heatsink. As you can see here, the cuts far from match up nicely. Oh well, I'll get it smoothed out, I always do.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1460.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1458.jpg

Now I have to make more cuts and stuff, and some of the areas I will be cutting away are actually areas that show me how the two pieces line back up. So, I got everything lined up pretty, then drew the outilne on paper, so now I have a template, should anything happen.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1457.jpg

Then I started cutting away even more of the heatsink, to acommodate the pcb that's larger than the screen.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1471.jpg

That's as far as I got then my dremelike started smoking pretty good. Whoopsie, guess that means I need to take a break. Oh yeah if you havent figured it out, I got a new dremelike. The ol' Black and Decker RTX, as well as a new flexshaft. Here is a pic I took trying to capture the smoke;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1465.jpg

I really like it. Smooth, quiet... course my Craftsmen dremelike was older than three of my kids so I guess anything would seem quieter and smoother. My flexshaft is quieter, too. Think my old one was no good to start with maybe.
One more thing, I cut away this section on the side. Gonna put wire mesh there instead, and make it blend into the sides of the heatsink. The other side is cut identically.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1463.jpg

Left me with this nifty lookin piece of scrap.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1464.jpg

[Mark_Hardware]

Alright, got some more stuff done today.
Finished cutting out the material in the back, to make room for the pcb.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1473.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1474.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1478.jpg

And, just when I was finishing the last bit,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1472.jpg

Dammit! This crap is going to fight me every step of the way, I swear. Can be fixed, but more pita....

Now I need to cover and build up the bottom. Recognize this piece?
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1476.jpg

No? How about now?
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1477.jpg

I'm after the bottom of this. It has the angled front, like the rest, so it should match up nice...
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1481.jpg

Or not.

So, here's the little bit of plastic I cut off the bezel for the monitor to the rescue.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1483.jpg

Obviously it's not level, but that will get fixed. All in due time.

If that stupid heatsink hadn't broke in half it would have been an even cut. [/expletives]
Then I'll sand this excess plastic down so its nice and flush....
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1484.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1485.jpg

Also, I got to use my "modders mesh." Working out pretty nice, I think.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1486.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1487.jpg

Here's a little sneaky-peeky at what's in store here.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1490.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1488.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1491.jpg

That picture was a nightmare to capture, so I took several, so you can get the idea. It looks sweet.
Got lots and lots of JB Welding to do tonight. Gonna fix the broken part I showed, fill the holes in the bezel by the monitors, and two parts of the front bezel for the mini-case.

[Mark_Hardware]

Small update today.
Lots of gluin' Filled in the speaker grills;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1507.jpg

Added some reinforcement behind the monitor bezel;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1510.jpg

Yay for globs of glue!!

Also fixed the broken part;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1504.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1501.jpg
I will slowly drill out the old useless glue, and refill with new, so it is nice and sturdy.

And, as far as this piece goes. I'm gonna nickname it the hemorroid cause it's such a pain in the arse! But see the difference in height? Thats cause it broke while cutting it. I decided that I am going to wait until I get another tool so I can make a nice straight, level, even cut here. So that's all for today.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1512.jpg
Sorry for the picture quality, light in living room is broke.

[Mark_Hardware]

Another not -so-great update. I didn't get to do much to my case, cause I did this-
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1565.jpg

sure, that part was easy. The part that was time consuming was soldering in extension speaker wirefor some of the speakers, cause the wires weren't long enough. Specifically the rears. Ironic, since my room is tiny.
Also, I had to work on my car. Trying to fix a door lock that isn't working right. Boy I'd like to shake the hand of the engineer who designed...... And next week I get to replace a blower motor. Oh what did I do to deserve this?
Anyway all I really did was sand and file. Woohoo who doesn't like doing that?

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1560.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1559.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1561.jpg

Nice and smooooth. I was going to cut out wire mesh for the sides, but I decided to wait until I get the bottom re-attatched so I know it will blend well.

[Mark_Hardware]

Well, unfortunately I don't have any actual progress right now, but I do have some exciting news; parts!
Courtesy of
NZXT,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1641.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1642.jpg

A brand spankin new whole front fascia. The took a look at my work and sent me the part I asked for free of charge.
Thanks NZXT, you guys rock!

[Mark_Hardware]

Well, I finally got some appreciable progress done today.
First, I cut a hole in the mobo tray for access to the cpu cooler. Not exactly foward thinking, but it's a nice addition.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1656.jpg

I flared out the sides around the screw mounts, just in case. Ok just for the heck of it.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1662.jpg

Speaking of the cpu cooler, I decided to add a layer of plexi to make it a little thicker, and hold more pressure against the cpu.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/5-30-2009092.jpg

I also cleaned up the edges of the various cuts. I had planned on filing them straight, but I decided that sucks so I just used my dremel.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1664.jpg

Not too bad, actually. Not perfect, but close enough for government work. The edges are not sharp at all, but I probably will give em a little sanding, just for fun. (huh?)

Gots to do me some measurin. I'm taking measurements for the 'wire channel.' I had some pieces actually cut for this already, here's an older picture of it;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_0299.jpg

but I decided to incorporate the ram cooler into it. So, I measured, and I cut and I drilled and her we go,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1657.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1658.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1659.jpg

a ram cooler. Or, as the say in France, ze ram coola
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1661.jpg

I will file the holes square, (sound familiar?) and I will put spacers between the fan and the panel, so it wont restrict airflow. I may put some mesh in there, to better hide the fans .

Speaking of mesh, (like the seque's here?) I am kinda thinking of using this panelling for the right side. Too many times the right side goes neglected, ignored. I am thinking I'll use this, with some mesh behind it so you can't see through it.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1665.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1646.jpg

I had also took the heatsinks off the mobo, to replace the TIM. I had heard it helps.
Here is my 790i digital nekked;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/5-30-2009077.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/5-30-2009074.jpg

now now boys, it's not polite to stare.

[Mark_Hardware]

Woot woot! Free stuffs! Got a box o goodies today from the Fedex man, courtesy of NZXT.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1716.jpg

New side panels, (I only asked for the right side but hey)
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1717.jpg

NZXT shirt. In case you haven't noticed, white isnt really my color, but I am happy to have the schwag and will for sure wear it!
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1718.jpg

case screws and of course,

the piece de resistance,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1719.jpg

a NZXT Sentry LX fan controller!

Here is a not-so-good picture of it next to my iMon,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1720.jpg

and one with flash
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1723.jpg

sorry, I had a hard time getting a decent pic, but it's a great match!

I am editing my first post to say "sponsored in part by NZXT"

[cool_clint_15]

BLOODY HELL!...I wish NZXT would send me stuff like that.

[Joco]

Yea, I have always wanted an NZXT t-shirt, I could even pay for one....

[Mark_Hardware]

update for today; I spent today working on the right side panel.
Started with this, and cut it down to the right size.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1732.jpg
(that pic came out crummy)

Dammit all.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1733.jpg

Size down,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1735.jpg

existing panel cut,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1736.jpg

fits nice.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1737.jpg

Started filing down the edges,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1742.jpg

decided that sucks big. Time to call in the backup
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1743.jpg
oh yeah.

sanded down most of it,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1741.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1738.jpg

will sand down the rest later.
Here's the plan, brace it with strips from behind. Hold everything together with rivets while the JB Weld dries. After JB dries, drill out rivets, fill the holes and the gaps. Result; a seamless panel on the outside. Hopefully.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1747.jpg

A pic of it on the case so you know what it looks like;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1748.jpg
Also I am gonna put mesh in the slats so you can't see through it.

Here's how it sits right now.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1751.jpg
cheers

[Mark_Hardware]

Little update today, just wanted to show how the side panel is turning out.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1754.jpg

Not too bad! I am happy with it. I ground the rivets flat, and sanded down all the JB Weld. Next just need to give it a little bondo lovin.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1759.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1760.jpg

Miniana, I start working on the side panel for the minicase
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1755.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1758.jpg

[Mark_Hardware]

Well, here's my update for this week. Been working on the side panel for the minicase. Meh the steps were identical, with one exception. See, I took one regular side panel, cut out the middle section, then sandwiched the two together. Why? The result;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1814.jpg

A nice folded edge on both sides. This will ensure the side is nice and flush, top and bottom. I could not have done that by hand.

Here is the smaller side panel, with the last side all clamped up.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1826.jpg

Slapped a coat of bondo on it,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1839.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1842.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1840.jpg

Here's another side by side so you can see how the line up;
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1817.jpg

That's it for today. Hmm seems like it would have been more... Sure as hell felt like more....

[Mark_Hardware]

And now, ladies and gentleman, for my next trick, I need a volunteer. Anyone will do, yes

you sir, up front,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1849.jpg

come on down!
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1850.jpg

Now watch, as I turn one ordinary needle file and one ordinary jigsaw,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1851.jpg

Into the Mark Hardware Filing Machine 2000!
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1854.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_1855.jpg

In action;
YouTube - 100 1858
mwahahaha!
you all remember the last time I filed a bunch of holes like that. To heck with that!

*note to self, do not have wife hold camera anymore

[cool_clint_15]

Im really liking the ipod dock and the huge heatsinks being used. If and when I ever get the money I will mod my computer case

[Mark_Hardware]

Heyyyy its a boy!!! I just had my 6th kid today, 5 boys now!!!!

[iNZXT]

Congratz! 6 kids :erstaunt078: and 5 of them boys, sounds like trouble.

[cool_clint_15]

Holy crap, Congrats on that!

[Mark_Hardware]

thanks guys!

[Mark_Hardware]

Heeeya! *cough cough* *blows away the dust* Is anyone alive in here? Helloo?

OMG, its alive!!

That's right suckas, I'm back in action! Took me a little hiatus there. Between work and school and a

string of disenheartening FAILures I just had to take a break for a while. But with tax season here, That

means new parts are just around the corner! As soon as my employer quits draggin *** and gives me

my W-2 that is :p

Started out by working on something kinda simple. I call it the wire box, for lack of a better term. See,

one goal of this project is to see no wires what-so-ever. The back of the case (where there is usually

the most wires) is no exception. This box will serve to hide these cables. I am thinking I may add a hub

here, to make everything accessible at this point instead of having to get to the I/O panel.

So this wasn't too complicated, just add some alum channel,

make a frame,
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2917.jpg
curse, swear,

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2902.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2905.jpg

My first day back to real modding and it's like I never left. This stoopid piece broke during drilling.
That's ok, I will fix it, make it stronger, make it better.

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2907.jpg

Anyway, here is that, attached and happy.

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2908.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2910.jpg

I also started working on the upper front pieces. I cut and sanded the plastic and replaced it with wire

mesh. Both sides will be identical. I also started blending this piece of heatsink into the front plastic. It

will have a similiar appearence to the bottom.
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2819.jpg

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2919.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2921.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2918.jpg

Just for funs, I hooked up this key switch. Originally I wasn't going to use it because it's too big, but I

have changed my mind, deciding that it's actually perfect because it's big. So say hello to my new

"on" button.

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2915.jpg

One more note, I have also come to the difficult decision to not use the front fascia, do to the exorbitant

amount of problems and ongoing design changes. What I have decided to do instead is use this piece

for experimenting on, and once I get everything figured out, I will make a final model. From now on I

consider this a prototype. I already have the parts lined up, but I am not making a single cut on them

until the prototype is done and I have everything figured out.

[Joco]

Seems really intresting! :) It's kinda hard to get a picture of how it is gonna look but I am excited to see so keep up posting progress and pics :D

[Mark_Hardware]

Woo hoo more!
Actually some kind of exciting progress for me. Been working on the heatsink for the front. (Gee that sounds familiar)
So I took my Mark Hardware Filing Machine 2000 and put a saw blade back in it.

BAM instant table saw! This was literally exactly what I needed to cut this plastic right.
(Action shot!)

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2922.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2925.jpg

Also, it worked fantastically to cut some of the unwanted material off this heatsink.

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2927.jpg

An after shot;

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2937.jpg

Now let me say this! I do not advise doing this. It just doesn't seem like the safest thing. I
mean, it may just be my opinion, but it seems like a great way to lose a finger. My wife concurs with me. Everytime I use it. Also, I don't want to get sued by any 9 fungered modders cause I gave them the idea. My wife concurs with me on that, too.

Anyway I'm also have been removing some material to mount the red lcd screen. I'm not too worried about having it as a temperature readout, I just like the red screen.

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2933.jpg
http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2936.jpg

So here is what its looking like.....

http://i587.photobucket.com/albums/ss312/Mark_Hardware/100_2929.jpg
Me likey!!!

[v4rj04nkk4]

cool..now you can play Tetris.. :D