Project: Aluminum Water Cooling Case

[Bob2701]

Glad to see the pics are coming again Rich. Can't wait to see the finished product. Great job.

[aryan51]

me 2

[Spotswood]

The three pieces of "false" back were attached to the bottom shelf via three pieces of 1/2-inch angle and some socket cap screws.

[Doctor_Death]

Hi Rich

I'm going to send you a PM

[Spotswood]

Up until now the front of the case has been held on with masking tape, but its now time to attach it securely. I had originally planned on drilling through holes and bolting the front to the case, but there wasn't much room for my hands to hold onto a nut, so I increased the size of the through hole a bit and pressed-in some PEM nuts.







The front frame consists of 1x1 and 1/2x1 u-channels.










Button head bolts were used to attach the front to the case.

[ReU_VOoDOo]

Looking great rich! I must applaud you initiative. Are you a sheet metal worker by any chance?

[Spotswood]

Looking great rich! I must applaud you initiative. Are you a sheet metal worker by any chance?

Nope. Software engineer by day, custom case builder by night.

[Spotswood]

The side panels were cut via the help of a large makeshift square made from a small square clamped to a ruler.










The radiator ventilation cutouts were made with the help of a router template. Some bits of scrap aluminum were bolted to the underside to eliminate any errors with placing the template accurately on the sheets.







Determining where to make the cutouts was easily done via a dab of India ink on the head of a screw and some masking tape. The panel was repeatedly pushed up against the inked bolt.

[ReU_VOoDOo]

Looking good Rich, nice trick with the ink. What ga. and type of Alm are you using?

[Spotswood]

Looking good Rich, nice trick with the ink. What ga. and type of Alm are you using?

.10-inch thick 5052

[Spotswood]

In order to accurately drill the bolt holes to attach the perforated aluminum to the side panels, I fabricated a drill template from some left over flat bar stock and a drill bushing I had lying around the shop.





A couple of spacers was used to quickly and accurately place the jig on the work piece (to avoid having to measure/layout the location of the holes).







Some .063 perforated aluminum cut to size:









To accurately cut the rounded corners on the side panels a router jig was fab'd from a piece of the corner round used on the body of the case, 1-inch u-channel and a couple of 1-2-3 block hot glued to some particle board. Two strips of Mylar from an old drum head was used to smooth out any irregularities.







Tah-dah!

[Spotswood]

Another requirement for this case is a hidden door latching mechanism.


Look Ma! No latches!







A length of .125x.75-inch flat bar was bolted to the bottom of the door to act as a lip that will hook into the u-channel along the bottom of the case, for example:







Along the top of the door, there is a piece of angle with three "hooks", which were routed out using a cobbled together router template.










A thick piece of flat bar was filed down to where it'll slide easily inside the u-channel along the top of the case. To that three "posts" were bolted to it. When slid forward, the posts will engage the hooks.

[spechtrevent]

This looks like a very great case so far. Looks like it could take quite a beating with that much aluminum.

[Spotswood]

A large area of the right side panel was cutout for a 16x15-inch acrylic window.

[vinman]

Awesome build keep the pictures coming looking really good my friend!!

[m.oreilly]

just discovered this thread...most impressive!