Engineering Help Appreciated for WC setup

Just a couple of thoughts.

1. SS is a poor conductor, so don't forget to ground everything to a common spot like the psu or mb tray.

2. Great idea to use the tubing as distribution headers. Be sure to insulate your 'cold' side tubing so it doesn't 'rain' iside your case! That'll also prevent any 'preheating' prior to your blocks as well.

3. You're gonna get some turbulence at those square corners that will cause pressure drops (slight) and decreased flow (little more than slight) at those points as well. What pump are you gonna use?

The concept is pretty 'cool' (pun intended) with the header idea. I keep seeing visions of organized barb locations, integral radiator, built in air purge, and a hot side bypass setup to run an additional loop in those hot summer months.....

Quote:

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Originally posted by GLScooby
Just a couple of thoughts.

1. SS is a poor conductor, so don't forget to ground everything to a common spot like the psu or mb tray.

3. You're gonna get some turbulence at those square corners that will cause pressure drops (slight) and decreased flow (little more than slight) at those points as well. What pump are you gonna use?

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Thanks very much for your ideas, I hadn't even considered the first yet. As soon as I get a chance I'll head out to the garage and conduct some "real-world" tests with my multimeter and a battery.

Your third point embodies all of the problems that I originally considered. My plan for pressure drops and flow problems is to keep high priority circuits close to the pump and handle things from there. If it becomes a real problem I could round the corners of the frame at the loss of some aesthetic value.

The pump has been the hardest decision to make so far. I really have no idea how much power I will need to make the distribution header work correctly. The frame is two 22" squares of .75" SS square tubing so you have just as much info as I do. Anyone have any ideas?

Edit: Forgot the story I wanted to share:

The air compressor that I was using to do all the work on the case just couldn't keep up with the abrasive disc and die grinder so it was time for a new air compressor. Fast foward to last night 11PM when I was just finishing up hard-wiring it into the 230V circuit in the garage. I decided to wait until morning to test it. This morning I switch on the circuit breaker to have the all the lights in the house go dim. Two hours of troubleshooting and breaker flipping later I figure out that I wired the switch wrong, so that when you turn it on it connects the two hot lines. :eek: I know my computer survived, but god only knows the beating my little APC surge protector took!

Just got back in from the garage. From what I can tell with my multimeter the frame has good conductivity from just about every part.

Update Time:

Finished the mobo rack except for the expansion card holders which are going to be a major job. I also installed the mobo and three HDDs to see how eveything fit. It looks and the case is getting pretty heavy with the the hardware and support bar I added.

The bracket: http://members.lycos.co.uk/zackbass1/Mobo_Bracket.jpg

The whole case so far: http://members.lycos.co.uk/zackbass1/Mobo_Side.jpg

Looks like it is coming along very well :) :)

So where is the top of that hard drive???

Those two drives were broken BEFORE I removed the covers :D
They used to serve the purpose of cool looking speakers but now they are mock-up parts.

Now for the long awaited daily update!

I finished the PCI and AGP brackets today and istalled the first large drive bay.

I also did some "strength testing" of the frame.
http://members.lycos.co.uk/zackbass1/StandingOn.jpg
Let's see a Lain-Li do THAT! And no, I'm not some scrawny nerd, I'm 6'4" and 220lb.

And here's a pic of the PCI and AGP card holder:
http://members.lycos.co.uk/zackbass1/PCI&AGP.jpg

Very nice work there bud...

Just make sure you are not shorting out anywhere :)

thats a sweet setup in the works!!!

and dammit i am fatter. i am 241 and 6'4" :(

Awsome work keep it up. Will you put casters on the case? It needs casters :D

Update Time! :D (groans heard from audience)

I finally got my radiator installed into the case. It's actually two small transmission coolers ($16 a piece :)) with a tube between them. I didn't have a good place to fit them inside the case that worked with my airflow plans so I added a top piece onto the case. It not only protects the fragile cooler but is very stylish! I also got the sheet metal I will be making many of the side covers from. It's .036 stainless sheet and looks pretty good from the testing I've done so far.

http://members.lycos.co.uk/zackbass1/RadiatorTop.jpg
http://members.lycos.co.uk/zackbass1/RadiatorBack.jpg

Great work!

But when I look at the size of that case compared to the mobo... GOD DAMN is that big! :eek:

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Originally posted by Colossus
Great work!

But when I look at the size of that case compared to the mobo... GOD DAMN is that big! :eek:

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just more space to work... It's better to have lots of space than to be cramped....

And also, you're both too thin, I'm 6'3" and 280.

It's everyone's favorite time again, that's right: Update Time!

Premise: The time of year is spring, you know, the time when people take the covers off their swimming pools.

I have a steel frame with an unknown number of microscopic holes in it that must be fixed, if I can find them.

Coincidently, I also have an air compressor and a number of pipe fitting.

Edit: forgot to mention that using the air compressor, I pressurized the frame to 80psi.

I end up with this:

http://members.lycos.co.uk/zackbass1/Setup.JPG

And this:

http://members.lycos.co.uk/zackbass1/Test.jpg
Now that's what I call a boat anchor!

Besides finding several extremely small holes, I can't think of a better way to prove to everyone that the mock-up parts are are only that, they don't actually work. You have no idea how many times I have told that I shouldn't be using good parts to bulid around!

I know that you can't wait for more updates :p, but that's the best I can do.

That's an awesome way to test for leaks! So once you get those holes welded shut and a pump installed are you gonna fill that frame up soon? I'll bet that will be an interesting day, I can't wait to see pictures of that:)

Very nice! I wouldnt of done it any other way too test for leaks :)

So if the water will be passing around the metal frame.. What would you to determine water level?

Quote:

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Originally posted by Colossus
Very nice! I wouldnt of done it any other way too test for leaks :)

So if the water will be passing around the metal frame.. What would you to determine water level?

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You mean the water level during normal operation, right? I plan to just fill it up and check the level once a month maybe. If that is too troublesome it wouldn't be too hard to install a sightglass for the water level.

There's just a few things to finish up before I start it running:
1. Finish all the side covers (in progress)
2. Buy a pump
4. Buy waterblocks and other small items
5. Finish welding on the threaded fittings once I know where I need them to be

I hope to work out some good hours for my job this summer so I have a lot of time to work on this project. The sheetmetal cutting and welding is extremely tedious work as I don't have a shear or brake. Everything has to be drawn out and cut with the plasma cutter by hand.

Oh well, it's not like I'd rather be doing anything else!

Quote:

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Originally posted by zackbass


Oh well, it's not like I'd rather be doing anything else!

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Ah, a true modder.

This is absolutely incredible! Hats off to you! Keep us posted (as you have been).

Are you using this project as a means to learn welding, etc. or did you already have the skillset to some extent?

Quote:

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Originally posted by Tripitz
Are you using this project as a means to learn welding, etc. or did you already have the skillset to some extent?

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I didn't have much experience with welding when I started. I had done a lot of MIG welding but had only done few small repairs using the TIG. Most of what I knew when I started I learned from a book on welding.

I have learned a lot from this project so far. Almost every welding position and material type and shape has a different feel. The most valuble things I've gotten out of it are an extremely steady hand and practice.

Quote:

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Originally posted by zackbass


I didn't have much experience with welding when I started. I had done a lot of MIG welding but had only done few small repairs using the TIG. Most of what I knew when I started I learned from a book on welding.

I have learned a lot from this project so far. Almost every welding position and material type and shape has a different feel. The most valuble things I've gotten out of it are an extremely steady hand and practice.

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That's awesome that you are learning a lot from this. Its funny, but I find the learning part the most enjoyable part of the modding process. I learned a lot when I put my wc rig together and it is already giving me more ideas. Now all I need is a welder... :)

Wow that's a really cool case :) I was looking at the pic of it by the pool thinking 'It would suck to have that fall in..' then I see it underwater lol :)

Make sure you keep this thread updated.. Also I had no idea everyone had to be 6'4" to post in here.. hell I'm only 6'2" 215.. <eats Big Mac (not the member sickos)> ;)

7.14.03....Updated Intelligence Report....Classified

I haven't gotten around to do much on the case until recently. I've been doing way too much car modding for the past few weeks.

Now that I am working on the case again I have been making some progess with sheet metal work. The right side panel (or the driver's side in car terms) has just been finished and installed. I just have to put the finish on it with the little 3M pads.

http://members.lycos.co.uk/zackbass1/Side_Panel.JPG

Here's the back side of one of the little fasteners that hold the panel on.

http://members.lycos.co.uk/zackbass1/Fastener.JPG

And here is a picture of the tubing routing for the coolers. I used normal fuel line hose and metal hose clamps. Hopefully flow won't be too much of an issue. You can see the bungs welded onto the frame (thanks for the idea Jubjub :)) which were 304 stainless pipe couplers that I cut in half and the barb fittings screwed into them.

http://members.lycos.co.uk/zackbass1...tor_hookup.jpg

And I'll finish with a question: Because the radiator will be a low flow system, do you think it would be better or worse to make two different coolant circuits? One that takes coolant from the resivor and thoughout the waterblocks, and a separate system (with or without a separate pump, dunno which yet) which would run the coolant from the resicor through the radiator and back again.

I finally got motivated to finish this project off, so I decided to splurge on parts today and everything I'll (hopefully) need. I just ordered the following from Voyeurmods.com:

Eheim 1250 pump
Vantec 520 watt PSU
4 120x120x38mm fans
2 aluminum 80mm fans
12" red cold cathode

The shipping was bit expensive to my taste: $25 (That's how much it costed to ship the inital 30lb of steel from Redmond, WA!) But what's $25 on top of $250. ;)

I was going to get the larger Eheim pump, but decided against it. I don't think my lines are big enough to make use of such a large pump. I also decided on the 520 watt Vantec because I am having problems with my Antec SmartPower in my current rig. I also want to have as much headroom to work with a possible as I hear the new Intel chips are going to be sucking down the juice.

Great work, I am happy to see that this is moving along so nicely.

w00t! I finally have all the parts necessary to finish the "Master Plan" *manaical laughter* otherwise known as my comp case. Here's some .JPGage (just made that up):

http://members.lycos.co.uk/zackbass1/New_parts.JPG

I already mounted the pump in the case. It's sitting on top of some rubber fuel line hose to stop any vibration. I didn't realize what I was missing with the pump in my current case. This Eheim runs like a 1972 Chevy Caprice. Smooth and powerful.

I tried out all 6 fans together and they seem more quiet than the two front fans on my PC-60. I don't really have any plans for fan placement, so if anyone wants to suggest something, please do.

When I ordered the red CC (not in pic) I missed that it was just an extra bulb and not the whole setup. Hopefully I'll be able to steal the necessary electronics from my old scanner.

I didn't realize how good the PSU looked until I took it out of the box. It's the most beautiful PSU I've ver seen. Hopefully it'll be up to the task of some heavy P4 OC'ing.

Also received was a 24"x48"x1/8" plexi sheet for the left side of the case. I've been cutting it with a sawzall (don't have a jigsaw) and it's been going pretty well, but not perfectly.