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Peter Brands

L3p AlCu

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Here a small project :)

The TC-100 is already an out of production case and was a present from Marco en Ruud van Cooler Master Benelux.

Always wanted to do something with passive cooling!

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Cause it was a really busy year for me I wasn't able to find the time for it...

Finally found it!

For the support I got from several company's I though, why not make is a small project :)

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My plan is to get this working as a passive cooled htpc/internet pc with a Corsair logo (I have something with sailing boats lol) window and brushed aluminum look.

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Hardware:

Cooler Master TC-100

Cooler Master Copper passive cooling kit

Lian Li SD-03A Case Stand Silver

AC Ryan Aluminum brushed 1mm panel

Lamptron 19mm switch blue

Intel Core i3 2120T

Asus P8H77-I

PicoPSU 150XT

Corsair Dominator Platinum 8GB 1866Mhz

Corsair Neutron GTX 120GB

Corsair Vengeance K60

Corsair Vengeance M90

Big thanks to:

cm.pngcorsair.png

asus.pnghighflow.png

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The hardware.

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Don't know why, but I just love brushed aluminum.

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Won't be much left of the original steel frame.

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Will also replace the front since it won't have a dvd/blu-ray player.

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Can't wait to figure out the cooling as the original kit was designed for real old VIA chipset mainboards :)

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At first it was going to be an AMD setup but cause of some driver issues and heat problems I went for an intel based setup.

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Also ordered a PicoPSU 150XT.

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The H77 board.

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And the Intel i3 2120T (35W)

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So glad Corsair wanted to help out on this little project!

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First run with the new psu went perfect.

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Without any airflow it gets pretty hot :)

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Set of aluminum Lian Li casefeet.

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Outside all Alu.

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Next update the heatpipes.

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So ... got everything off my attic :)

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Ohh boy :P

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Just love untreated copper.

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Ever seen a Cooler Master heatpipe bending iron? :)

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Because these sets are originally for VIA chipsets it was quite a puzzle.

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This'll be it. Left for the CPU with 4 heatpipes, on the right, 2 pipes for the chipset.

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While I was at work I came up with a solution for the front with unwanted DVD slot.

Just make a new one :)

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Because it's about $4 a kilo I also took 2 bigger panels for if I ever want it to support ATX.

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Finding the right size logo for the casewindow.

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Further with the copper.

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Was looking for a way to mount it all .. luckily I had an EKWB bracket left somewhere.

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Will probably become something like this.

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First need to clean it up and shorten the bolts.

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Nice mess again :D

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To get the EK bracket working with the copper parts I had to change some parts.

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Bottom with just 4x M4 and plastic rings.

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Top with a nut and MDPC-x cap.

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And measuring again.

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Decided to just replace the front panel only. (Not add a back one)

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Getting the tools from the car.

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The panels are pretty damaged, will be quite some sanding.

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Getting the switch in the panel.

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Larger update this time!

(For the ones who didn't know, all my photos are linked to bigger ones)

Finally able to use the investment I did a year ago :)

AC Ryan Brushed alu panels.

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Lets get the grinder first.

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Hi

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I'm going to use the brushed aluminum on both sides of the original bottom/mainboard tray.

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Panel for the bottom, will be using acrylic on top of that.

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And the inside, or mainboard tray.

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Measuring and fitting the bottom panel.

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And again measuring and fitting with the mainboard.

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This is how the bottom will look.

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Drawing the panel for the casewindow.

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And used the grinder to cut it out, also cut a hole in the original panel.

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Cutting the logo in the right size.

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Determining the spot.

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Drawing it on the aluminum.

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Cutting out the logo with my fully automated lasercutter with built-in footpedal and spotlight.

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Lots of filing and sanding to do afterwards.

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Polished the thin edges so they will shine.

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Glued the alu panel to the original panel.

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Also glued in the acrylic panel.

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Measuring the exact spot of the copper parts.

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Drilling and tapping.

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Determining the holes to attach the new front panel.

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And again drilling and tapping...

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Cleaned up 2 out of 3 desks on the attic to move on there :)

(As in, all the mess is on the third now)

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Shortening the bolts so I won't damage the cpu.

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Can't wait to test it all to see if it actually works.

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Testsetup :)

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First boot in bios is always exciting .. but looks good.

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Light stress, 65 degrees max .. works for me.

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Next test, streaming blu-ray for 3 hours.

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Temps were between 40 and 50 degrees.

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With light from the original powerbutton.

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Next update ... more light :)

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To start off right .. an update .. and ..

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Let's get rid of all the cables.

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Where to hide them?

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Connecting the vandal switch.

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Shortening some cables for led and psu.

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Had some Enzotech heatsinks laying around and used them too.

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Testing the ledstrip and vandal switch.

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Psu and all cables :)

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Gone!

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Another full test and photos with flasher.

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And without flasher.

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Time to do something about the ssd.

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My idea is to make it a 'bit' shiny.

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Almost there.

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And a last shot before it disappears in AlCu.

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Done.

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My daughter is extremely happy with it!

Daddy's happy too as it's the first time since the new Xbmc he can see the DTS-HD notification on his receiver :)

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What's left to happen.

- Sanding the frontpanel.

- adding thermal paste between all the heatpipes and copper side plates

- adding a Cooler Master logo.

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Thanks Rodrigo!

And another small and last update.

First disassembled all copper again.

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To get some thermal paste between it.

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And cleaning it all afterwards.

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Disassembling the front panel.

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To start sanding again.

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Also did something else with the SSD.

Wet sanded it with P2000 which gives a non mirroring nice shine.

After sawing a Corsair logo into the Cooler Master case .. well thought it would be nice to add a Cooler Master logo somewhere too :)

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More sanding.

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And even more sanding.

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Finally the result I wanted.

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So assembled it again.

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And a few photos before powering and testing it again.

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Also a few in daylight.

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Oops ... wrong wire..

Not even that weird :)

(ssd also still not attached)

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And a final test with temperatures.

Idle 40-45 degrees, stressed 70 max.

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Hereby the final photos.

I have to say, I really liked this small project, a complete different thing.

Also very weird to have a running pc making no noise at all ... 0dB.

AlCu2_final.png

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I want to thank the following companies for all their support the last 2 years!

cm.pngcorsair.png

asus.pnghighflow.png

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