Nicholas Falzone

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Everything posted by Nicholas Falzone

  1. _A080269 by greensabbath911, on Flickr _A080262-Edit by greensabbath911, on Flickr _A080261-Edit by greensabbath911, on Flickr _A080250 by greensabbath911, on Flickr _A080248 by greensabbath911, on Flickr _A080239-Edit by greensabbath911, on Flickr _A080236 by greensabbath911, on Flickr _A080233 by greensabbath911, on Flickr _A080216-Edit by greensabbath911, on Flickr
  2. _A080314 by greensabbath911, on Flickr _A080313 by greensabbath911, on Flickr _A080309-Edit by greensabbath911, on Flickr _A080308 by greensabbath911, on Flickr _A080306 by greensabbath911, on Flickr _A080298 by greensabbath911, on Flickr _A080296 by greensabbath911, on Flickr _A080292 by greensabbath911, on Flickr _A080290 by greensabbath911, on Flickr _A080288 by greensabbath911, on Flickr _A080287 by greensabbath911, on Flickr _A080286 by greensabbath911, on Flickr _A080275 by greensabbath911, on Flickr
  3. _A090360 by greensabbath911, on Flickr _A090356 by greensabbath911, on Flickr _A090355 by greensabbath911, on Flickr _A090353 by greensabbath911, on Flickr _A090343-Edit by greensabbath911, on Flickr _A090338 by greensabbath911, on Flickr _A090337 by greensabbath911, on Flickr _A090336 by greensabbath911, on Flickr _A090331 by greensabbath911, on Flickr _A090321 by greensabbath911, on Flickr _A090318 by greensabbath911, on Flickr
  4. I present to you the final photos for Morphosis: _A090404-Edit by greensabbath911, on Flickr _A090407 by greensabbath911, on Flickr _A090391 by greensabbath911, on Flickr _A090401 by greensabbath911, on Flickr _A090400 by greensabbath911, on Flickr _A090390-Edit by greensabbath911, on Flickr _A090385 by greensabbath911, on Flickr _A090376 by greensabbath911, on Flickr _A090374 by greensabbath911, on Flickr _A090370 by greensabbath911, on Flickr _A090363-Edit by greensabbath911, on Flickr
  5. With the watercooling loop done and most of the machining settled I turned my attention to the cabling and cable management. My plan was to individually sleeve each cable with custom sleeving. I can see why after doing this, that most people buy them because it took forever but it was a rewarding experience in the end. First I made pinouts of all the cables: _A060134 by greensabbath911, on Flickr Heres the sleeving I'll be using. Silver and Black Teleios sleeving from Mainframe Customs: _A060136 by greensabbath911, on Flickr Pins and tools: _A060135 by greensabbath911, on Flickr The plan is to melt the sleeving using the heatshrink. Clear heatshrink enables me to see how melted it is: _A060141 by greensabbath911, on Flickr _A060138 by greensabbath911, on Flickr The cpu power cable is all done: _A060143 by greensabbath911, on Flickr Working on the 14 pin cables for the GPU. This is where the pinout becomes super important. _A060147 by greensabbath911, on Flickr Half ish done: _A060152 by greensabbath911, on Flickr Somehow I had screwed up my pinouts so I had my smarter than I wife redo them for me: _A060156 by greensabbath911, on Flickr The pretty side of the cable is all done: _A060155 by greensabbath911, on Flickr Trying to tame this rats nest of cables: _A060159 by greensabbath911, on Flickr GPU cables installed, Its looking pretty clean: _A060162 by greensabbath911, on Flickr _A060163 by greensabbath911, on Flickr The back however needs some more work: _A070170 by greensabbath911, on Flickr Next came the 24 pin cable which was more like 27 pins counting all the double connections. This took an extra level of patience to complete. _A070165 by greensabbath911, on Flickr About 3 hours later, its all done: _A070172 by greensabbath911, on Flickr The last thing to machine were the covers for the wires on the motherboard tray to help keep everything organized. This took only a few minutes on the CNC to complete: _A080181 by greensabbath911, on Flickr _A080182 by greensabbath911, on Flickr The case is built and ready for final photos: _A080178 by greensabbath911, on Flickr _A080175 by greensabbath911, on Flickr
  6. Back to the Power supply mounting and cover. I had the power supply mounted so I could make the cover plate for the mount: _A050087 by greensabbath911, on Flickr _A050078 by greensabbath911, on Flickr I drilled out space for the bolt heads below to fit into: _A050079 by greensabbath911, on Flickr Much cleaner than before: _A050081 by greensabbath911, on Flickr _A050091 by greensabbath911, on Flickr The sharp corner on the GPU mount was bugging me so I decided to chamfer it: Before: _A050093 by greensabbath911, on Flickr After: _A050096 by greensabbath911, on Flickr Next, I wanted to machine the name of the case mod into the GPU bracket piece. I used a thin piece of walnut and make a file to V carve: _A050069 by greensabbath911, on Flickr _A050071 by greensabbath911, on Flickr Cut to fit: _A050075 by greensabbath911, on Flickr _A050076 by greensabbath911, on Flickr With some finish on it: _A060122 by greensabbath911, on Flickr
  7. Time for more watercooling plumbing. I installed the processor and waterblock and started connecting the dots from there: _A040059 by greensabbath911, on Flickr _A040062 by greensabbath911, on Flickr _A050113 by greensabbath911, on Flickr _A050084 by greensabbath911, on Flickr _A050097 by greensabbath911, on Flickr _A050108 by greensabbath911, on Flickr Everything is mocked up at this point but not connected: _A050091 by greensabbath911, on Flickr After everything was finally connected, I got ready for leak testing: _A050115 by greensabbath911, on Flickr _A060120 by greensabbath911, on Flickr After a few issues were resolved, I had the loop filled and running properly: _A060121 by greensabbath911, on Flickr Its finally coming together: _A060130 by greensabbath911, on Flickr
  8. For the other case window, I wanted to mirror the design of the acrylic window but instead machine it out of solid aluminum. I made a file, and got to cutting. I will probably run one more finishing pass on the base of the cut to clean up the lines a bit more: Started off as a blank slate: _A030039 by greensabbath911, on Flickr _A030041 by greensabbath911, on Flickr _A030042 by greensabbath911, on Flickr I used an adaptive toolpath on this cut meaning it keep and even load on the cutter. This also helps me take a deeper cut. _A030043 by greensabbath911, on Flickr _A030048 by greensabbath911, on Flickr Starting the finishing pass: _A030050 by greensabbath911, on Flickr _A030052 by greensabbath911, on Flickr All done! I'll probably take off another .1mm from the floor to make the mill marks more even but I'm happy with the result so far. I'll be chamfering the edges of this panel once its complete. _A030054 by greensabbath911, on Flickr
  9. I can finally start some of the final assembly for the case. After finishing the pump/reservoir room panels, they are installed in the case: _A020023 by greensabbath911, on Flickr I have a sneak peek of the plumbing also. I'm using all Barrow fittings and 12mm chrome copper tubing: _A020025 by greensabbath911, on Flickr I wanted to make a support bracket for the GPU. I chose to make it out of a heavy aluminum bar stock I had laying around: _A020028 by greensabbath911, on Flickr I cut it to length, gave it a miter and screwed it into the aluminum bracket: _A020027 by greensabbath911, on Flickr _A020029 by greensabbath911, on Flickr Here it is installed in the case so far. I'll be adding to this soon: _A020033 by greensabbath911, on Flickr _A020034 by greensabbath911, on Flickr A bit more plumbing: _A030035 by greensabbath911, on Flickr _A030037 by greensabbath911, on Flickr A shot from the back: _A020031 by greensabbath911, on Flickr
  10. I was not originally going to use mesh over the fan grills but I decided to try it out and see how it would look: IMG_6602 by greensabbath911, on Flickr This is A.C. Ryan silver mesh. It is steel so it was not very easy to cut. I'm glad I tried this though because I think it turned out great. It really makes the grill design pop: IMG_6603 by greensabbath911, on Flickr IMG_6606 by greensabbath911, on Flickr I put it over the top grill too: IMG_6608 by greensabbath911, on Flickr I also installed the LED strip into the top, making it ready to be put into the case: IMG_6610 by greensabbath911, on Flickr IMG_6611 by greensabbath911, on Flickr _A020021 by greensabbath911, on Flickr Next, I wanted to make covers for the holes around the motherboard to help with cable management. I had some veneered aluminum still so I cut some of that to make a board around the motherboard. I can then mill these pieces to fit the cable design later: I started with the mitered corner: IMG_6596 by greensabbath911, on Flickr And I cut the rest to fit from there: IMG_6598 by greensabbath911, on Flickr _9300004 by greensabbath911, on Flickr They are in sections so I can mill some of them without having to take it all apart. They screw into the motherboard tray and cover holes behind them which will also be used for cable management. I made one for the CPU power hole too: IMG_6601 by greensabbath911, on Flickr The power supply mount is also getting an upgrade. I'm doubling up the support bracket so I can mount a cover on top of that: IMG_6600 by greensabbath911, on Flickr The cover piece will look something like this and get bolted on: IMG_6597 by greensabbath911, on Flickr _9300013 by greensabbath911, on Flickr I wanted to finish of the cover pieces to match the rest of the case so I brushed the edges of the aluminum and gave them a chamfer: _A030057 by greensabbath911, on Flickr _A030047 by greensabbath911, on Flickr
  11. With the corner brackets made, I could drill holes in the windows for the bolts. I taped the acrylic window to the aluminum piece underneath ti ensure the holes would line up: _9292972 by greensabbath911, on Flickr _9292970 by greensabbath911, on Flickr _9292982 by greensabbath911, on Flickr I then drilled holes into each support piece and tapped threads into each piece. The second window is going to be made out of 3/16 inch aluminum. I wanted a brushed finish to match the rest of the case so I needed to use my drumsander again to achieve this. Before: _9262915 by greensabbath911, on Flickr After: _9292940 by greensabbath911, on Flickr More on this piece later.
  12. One of the last tasks before I could finally start putting the case together the final time was making the attachment points for the two window panels. Two of these I have previously made but the other two needed to be done using the existing structure of the case. In each corner is a little corner bracket made of steel but it is too thin to put threads in so I wanted to remake it out of aluminum. The piece to be made: _9272938 by greensabbath911, on Flickr I modeled it in Fusion 360 and cut out four of them at the same time: _9292941 by greensabbath911, on Flickr _9292942 by greensabbath911, on Flickr I drilled the screw holes and then made the counter sinks to match the case panels: _9292960 by greensabbath911, on Flickr _9292963 by greensabbath911, on Flickr I threaded the holes and they were good to go: _9292964 by greensabbath911, on Flickr
  13. I finished the feet with a few coats of General FInishes Arm-R-Seal and now they are ready to mount to the bottom of the case: _9292949 by greensabbath911, on Flickr _9292950 by greensabbath911, on Flickr Checking the fitment to make sure the reveals are even: _9292952 by greensabbath911, on Flickr _9292953 by greensabbath911, on Flickr _9292955 by greensabbath911, on Flickr _9292956 by greensabbath911, on Flickr I fastened the case feet with four screws into each one. The feet have chamfers to help connect the lines of the case. Next, I turned my attention to the power supply shroud. I like the system that the case uses so I'm going to modify that. _9272921 by greensabbath911, on Flickr I have a bit of veneer aluminum still so I'm going to attach some of that to the shroud and blend it into the rest of the case: _9272918 by greensabbath911, on Flickr I wanted to make sure I had a nice mitered joint so I used some scrap wood to get the angles right: _9272922 by greensabbath911, on Flickr First piece cut, just making sure the fit is right: _9272924 by greensabbath911, on Flickr I cut the pieces close together to ensure the grain would carry over from one piece to the other: _9272929 by greensabbath911, on Flickr _9272930 by greensabbath911, on Flickr _9272931 by greensabbath911, on Flickr I also sanded the edges to give them a brushed look: _9272926 by greensabbath911, on Flickr With the panels attached to the shroud, I could mock it up with the Walnut panel I made last time. It has a couple coats of finish but is not entirely done yet: _9272935 by greensabbath911, on Flickr _9272936 by greensabbath911, on Flickr
  14. Next I wanted to make a wood accent piece that mimics the design of the case window and acts as a partition in the case. I modified the same file I used on the window to make it deeper and cut a test panel. I then mocked up the test panel in the case: _9252882 by greensabbath911, on Flickr _9242880 by greensabbath911, on Flickr I then milled some Walnut to the approximate size I needed. I paid special attention to the grain to ensure it would look cohesive. Here are the two pieces: _9252883 by greensabbath911, on Flickr Even without glue it is hard to see where each piece ends: _9252884 by greensabbath911, on Flickr After it was glued, I milled it to a bit over 1/2 inch thick and set it up on the wasteboard and got to cutting: _9262895 by greensabbath911, on Flickr _9262909 by greensabbath911, on Flickr All done but before sanding: _9262913 by greensabbath911, on Flickr All sanded and ready for finish: _9262916 by greensabbath911, on Flickr
  15. Back to the feet. I wanted to carve the feet and add some chamfers to them to match the asthetics of the rest of the case. I used a band saw, file, sand paper and a router to do this. Basic design sketched out: _9252885 by greensabbath911, on Flickr _9252886 by greensabbath911, on Flickr _9252887 by greensabbath911, on Flickr _9262897 by greensabbath911, on Flickr The front needed extra attention to match the profile of the front panel: _9252892 by greensabbath911, on Flickr _9252889 by greensabbath911, on Flickr _9252893 by greensabbath911, on Flickr All sanded and ready for finishing: _9262902 by greensabbath911, on Flickr Starting the finishing process: _9262911 by greensabbath911, on Flickr
  16. I thought about only watercooling the CPU but it made the most sense to watercool everything. I bought a reference Radeon 5700XT and the Ek Vector Waterblock to go with it: _1012859 by greensabbath911, on Flickr After installation: _1012862 by greensabbath911, on Flickr I also made a cover for the side of the case out of a piece of 1mm brushed silver aluminum, courtesy of A.C. Ryan. This covers the edges of the panels and gives the case a more finished look. _1012866 by greensabbath911, on Flickr
  17. As part of the illumination in the case, I will be using ARGB light strips. These will be going in the two sides of the Res/Pump room along woth in the ceiling of the main compartment: Here: _9172779 by greensabbath911, on Flickr And here: _9182791 by greensabbath911, on Flickr I made a model and got to cutting: _9182792 by greensabbath911, on Flickr _9172786 by greensabbath911, on Flickr I needed something to hold the actual strips though so for this I decided to route out a 3mm deep channel in some 1/4 inch acrylic: _1012868 by greensabbath911, on Flickr _1012871 by greensabbath911, on Flickr _1012873 by greensabbath911, on Flickr Perfect fit: _1012874 by greensabbath911, on Flickr _1012877 by greensabbath911, on Flickr
  18. The case has an interesting power supply placement and holding solution that I liked so I wanted to incorporate a modified version of it. Here is the contact point transferred to the new motherboard tray. IMG_6462 by greensabbath911, on Flickr I made a little bracket to take up the space between the tray and the power supply carrage: _9182815 by greensabbath911, on Flickr I used sandpaper again to give the piece a brushed look. Here is where it mounts in the case. _9182794 by greensabbath911, on Flickr Soon I will modify the rest of the power supply shroud to more closely match the rest of the case.
  19. Next up is the case window side panel. For this, i wanted to incorporate brushed aluminum and inset it into an acrylic panel for a clean and cohesive look. I made two models in Fusion 360, one for the acrylic and one for the aluminum. If I was smart I would've done the aluminum first so I could perfect the fitment of it while the acrylic was still on the cnc table but instead I cut the acrylic first: _9152767 by greensabbath911, on Flickr I used a 1/4 inch single flute endmill to machine out the space for the aluminum to sit: Almost done! IMG_6517 by greensabbath911, on Flickr All done! _9152771 by greensabbath911, on Flickr IMG_6520 by greensabbath911, on Flickr I ran a finishing pass to clean everything up. Unfortunately the aluminum didn't fit so I had to remount it to the table in order to recut parts of it. Luckily Fusion 360 is awesome so I could pick which contours I wanted to be cut more. This took a bit of trial and error but eventually i got it to fit quite snuggly. Here's the aluminum part mocked up on the case: IMG_6521 by greensabbath911, on Flickr And here it is finally fitting into the acrylic: IMG_6530 by greensabbath911, on Flickr Mocked up on the case. I need to work on attaching it to the chassis: _9152775 by greensabbath911, on Flickr I aIMG_6461 by greensabbath911, on Flickr l also cut a piece of acrylic for the inside of the front window section: _9192850 by greensabbath911, on Flickr _9192852 by greensabbath911, on Flickr
  20. I wanted to put the case together to see how it was looking. Here is the current state of it assembled: _9192838 by greensabbath911, on Flickr _9192840 by greensabbath911, on Flickr Here we have the front and top panels and some hardware installed: _9192846 by greensabbath911, on Flickr _9192855 by greensabbath911, on Flickr One more view for now, the top/front panels: _9192853 by greensabbath911, on Flickr
  21. I wanted to refine the shape of the GPU bracket so I first started with a chamfer. I used my router table and chamfer bit to accomplish this: _9182797 by greensabbath911, on Flickr Next, I wanted to make a bracket to help hold the card on: _9182800 by greensabbath911, on Flickr I used some extra veneer covered aluminum for this: _9182801 by greensabbath911, on Flickr I used sandpaper to give the piece a brushed finish. I started with 80 grit and moved up to 220 grit. I will use this for the rest of the small parts: _9182808 by greensabbath911, on Flickr A couple stainless 6-32 screws will keep it in place: _9182809 by greensabbath911, on Flickr
  22. I wanted to try a finish on the aluminum panels that would go with the casing on the outside. I have a drum sander I use primarily for making cuttingboards but I decided it might work to brush the aluminum also. The panels got pretty hot but in the end the effect turned out successfully I think: Here's the before: _9192829 by greensabbath911, on Flickr And the after: _9192834 by greensabbath911, on Flickr _9192835 by greensabbath911, on Flickr I did the same on the motherboard tray. The spots where it did not quite brush enough would be hidden by the motherboard: _9192833 by greensabbath911, on Flickr I thought it was time to cut the top panel of the case to get a better idea of how it is looking overall. I modified one of the fan grille designs to the size of cutout I wanted in the top, made a template, and decided where it should fit. _9182804 by greensabbath911, on Flickr I taped it too the wasteboard and after carefully zeroing the coordinates, I got to cutting: _9182806 by greensabbath911, on Flickr I roughed out the shapes then ran a finishing pass to clean up the last .1mm: _9182813 by greensabbath911, on Flickr I think it turned out pretty cleanly: _9182821 by greensabbath911, on Flickr _9182827 by greensabbath911, on Flickr And with it on top of the mesh. This should give the case some extra ventilation: _9192849 by greensabbath911, on Flickr
  23. With the floor of the case made, I could continue working on the Reservoir/Pump room in the front of the case. The hardware would be placed something like this: IMG_6487 by greensabbath911, on Flickr I took the design on the front aluminum panel and modified it to fit on the panel behind the Reservoir. I machined a practice piece to finalize placement. The watercooling tubing will flow from the radiator in the top into the reservoir, then it will go out the bottom through the pump into the rest of the case: _9142758 by greensabbath911, on Flickr _9142756 by greensabbath911, on Flickr For this panel, I did not want to machine the pieces all the way through but just the profile so that the machined aluminum and walnut burl veneer would make a striking contrast. The machining has started here: _9142761 by greensabbath911, on Flickr It turned out pretty clean: _9182817 by greensabbath911, on Flickr _9142764 by greensabbath911, on Flickr IMG_6523 by greensabbath911, on Flickr And with the front panel on: IMG_6513 by greensabbath911, on Flickr Then I cut the top and both sides out of the same material and attached them to eachother with screws and square aluminum: _9192843 by greensabbath911, on Flickr _9152773 by greensabbath911, on Flickr
  24. The next thing I did was start laying out the motherboard tray. This would be a ccomplicated piece since many parts of the case and hardware will be attached to it and determine the placement of other parts on other panels. To do this, I started with my trusty layout tool, an old motherboard: IMG_6490 by greensabbath911, on Flickr Once I had a layout that seems decent, I made a model in Cad and then attached the tray to my wasteboard: IMG_6495 by greensabbath911, on Flickr From there, I started cutting. I did not bother making a practice piece for this one: IMG_6496 by greensabbath911, on Flickr And heres all the cutouts besides the ones that I forgot to make during the first go around. There are ones for the power cables and peripherals that attach to the motherboard along with exit holes for the PSU cables. IMG_6497 by greensabbath911, on Flickr From there, I tested the layout with the actual motherboard I will be using, a Gigabyte Aorus Elite WiFi x570: _9122733 by greensabbath911, on Flickr IMG_6501 by greensabbath911, on Flickr With the motherboard placement finalized, I could cut the holes on the back panel which include the I/O plate, the GPU mount, and the PSU cable mount. I then attached the motherboard tray to the back panel with screws: _9132737 by greensabbath911, on Flickr _9132741 by greensabbath911, on Flickr IMG_6506 by greensabbath911, on Flickr To attach the GPU to the back panel, I would remake my plywood test piece out of aluminum. I had an issue while machining this so I had to use my older method of making a plywood template and then machinging it on the router table. To do this I use lots of double stick tape: _9142743 by greensabbath911, on Flickr _9142744 by greensabbath911, on Flickr Then with that cut. I needed to do the same on the back panel: _9142745 by greensabbath911, on Flickr And here it is mocked up in the case: _9152766 by greensabbath911, on Flickr I also needed to attach the floor panel to the rest of the case and for this I again used some aluminum bar stock and screws: _9142748 by greensabbath911, on Flickr _9142752 by greensabbath911, on Flickr
  25. The main color scheme for my case would be both polished and brushed silver, walnut wood, and black. To achieve what I wanted with Walnut, I would have to attach it to aluminum panels before it could me machined. The best way I could think of to accomplish this was with contact cement. To do this, I layed out all the panels and began covering the IMG_6447 by greensabbath911, on Flickr The walnut veneer took many coats since the veneer kept soaking up the glue but eventually it looked glossy, meaning there was enough glue on the surface to bond: IMG_6448 by greensabbath911, on Flickr Once the glue was dry I could carefully set the veneer over the aluminum and use a roller to squeeze out all of the air pockets and make a good bond: IMG_6449 by greensabbath911, on Flickr Once the glue was dry, I could finally start cutting panels for the case. I started with the back panel along with the motherboard try which would remain bare aluminum. I attached the panels together with square aliuminum bar stock and screws: IMG_6452 by greensabbath911, on Flickr IMG_6453 by greensabbath911, on Flickr From there, I could dial in the other panels with more test pieces: IMG_6460 by greensabbath911, on Flickr IMG_6450 by greensabbath911, on Flickr _9082723 by greensabbath911, on Flickr I decided to extend the "floor" fan grill into the front res/pump room to support the pump. Of course, this required another test piece: IMG_6469 by greensabbath911, on Flickr IMG_6470 by greensabbath911, on Flickr After a few tweaks I layed out the design on the final piece: IMG_6472 by greensabbath911, on Flickr And started cutting: IMG_6474 by greensabbath911, on Flickr IMG_6478 by greensabbath911, on FlickrIMG_6478 by greensabbath911, on Flickr About three hours later it was done. I had to stop the machine after each cutout to clean the tape goo off of the bit. I was worried the walnut veneer would chip but it turned out pretty clean: IMG_6479 by greensabbath911, on Flickr _9082727 by greensabbath911, on Flickr IMG_6486 by greensabbath911, on Flickr I repeated the same steps above for the top fan grill design. Its a good thing I made practice pieces because I messed up on a few parts that I wouldnt have caught otherwise: IMG_6484 by greensabbath911, on Flickr IMG_6483 by greensabbath911, on Flickr I machined some cutouts in the above piece to enable removal of the top section of the case. I also put some finish on the panel to see how the grain would pop against the silver aluminum: IMG_6508 by greensabbath911, on Flickr The walnut burl veneer's grain pops beautifully with a little finish on it: Before: _9092729 by greensabbath911, on Flickr After: IMG_6485 by greensabbath911, on Flickr And with the fans which will be mounted to the grill. I had them upside down in this photo though: _9142759 by greensabbath911, on Flickr Here's a couple of closeup shots of the bottom grille: _9142753 by greensabbath911, on Flickr _9142754 by greensabbath911, on Flickr