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mrc4nl

[scratch build] Industrial desk [finished]

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mrc4nl    0

Hi, my name is Frank van Dijk.
Last year i also participated in the contest but never finished. I Made a Drawer extensions for the desk, but never the actual desk itself. I contacted the mods, and I can enter this contest as long as I only post material that was made this year. a new scratch build. i will forget about the old one.
 
For the lack of a better name my desk is called "industrial desk" because it will have a (somewhat) industrial look to it. Whit metal exterior like aluminium.
 
The design.

1.png
 
2.png

As u can see i wanted something modern, different than those square desks. Also the motherboard will be at a slight angle rather than flat to the bottom.
I needed space for the Power supply unit but also for a 3 *hotswap bay. Because it will also will contain my server/Nas. I wanted to be able to swap hard drives without having to dismantle the desk. Thats why there is a small block sticking
out of the rear.
 
first update
As whit all scratch build i needed material first. one sheet of 18mm thick plywood to be precise. that would be more then enough to support the desk
3.jpg
 
I started building the rear end of the desk. The guide was helpful for cutting in straight lines.
4.jpg
then i cut the corners.
5.jpg
and this is the result ( i made 2 of them)
6.jpg
Unfortunately, i forgot to correct for the thickness of the blade so one part was 2mm short. i placed a anti-static bag in between so i would not glue the 2 together when i add a little glue
7.jpg
add some glue:
8.jpg
thats better 
9.jpg
Then i needed to plan where i would place the hotsway bay. The best way is by having the part and align it visualy.
So i had to take apart the server (it has been quite a time) 
10.jpg
in the meantime a added some walls to the part
11.jpg
i removed the harddrives and the front
12.jpg
now i had the psu and drive bay i could move the parts into the best location
13.jpg
 
end of update one. the next one will follow soon ( as it is November i made quite a bit of progress, so i have a lot of material that needs to be published.)

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mrc4nl    0
When the placement of the hdd bay was determined i needed to secure its position. So i made a couple op brackets:

14.jpg

the hole -layout is the same as a normal 5.25" drive. i looked up the form factor spec sheet and made a drawing on my pc and printed it at 1:1 magnification

15.jpg

pasted it on the the aluminium :

16.jpg

and drilled the holes on the right spot:

17.jpg

i tested it on a 5.25" drive, it did fit perfectly: 

18.jpg

the hdd bay could now be fastened

19.jpg

altough there needs to be room for the side panel:

20.jpg

suddenly something wet came out the skies:

21.jpg

i moved the workpiece inside the house, where i added the second bracket:

22.jpg

and filled the gap between the hdd bay and the side panel


23.jpg

 

24.jpg


almost done, the 2 psu's and the hdd bay had a location


25.jpg

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mrc4nl    0
a aluminium profile was needed to secure the PSU in place

26.jpg

there was airflow needed to get the hot air out of the center by the psu's

i drawed the outline onto a square piece of wood

27.jpg

drilled some holes:

28.jpg

not much later:

29.jpg

times 2

30.jpg

time to put the pieces in place:

31.jpg

now the other side had to be made, first the inner side

32.jpg

and the outher side too

33.jpg

pre-drilling:

34.jpg

and add some screws to hold it tight

35.jpg

almost done:


36.jpg

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mrc4nl    0
Another part had to be made: the bottom plate, it will be made out of acrylic , and bend into shape.

37.jpg

the front is at a angle, so the mould has to be to:


38.jpg

 

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as u can see only the left and right side have a angle the mid part is flat

 

the sheet of acryllic had arrived:

43.jpg

the mould was not finished yet, the side had to be at a angle too:

44.jpg

some sandpaper to make everything nice and smooth:

45.jpg

now i can start bending it into shape using hot air:


46.jpg

 

47.jpg


the main frame needed some extra support for the base plate:


48.jpg

 

49.jpg


and a cutout for the flat part:


50.jpg

 

51.jpg


i bought the acrylic sheet a with margins, now the sheet has to be cut to size:

52.jpg

my coat was coverd in sawdust:

53.jpg

and so was the machine:

54.jpg

some screws to hold it in place:

55.jpg

as u can see the sheet is dull, i used sandpaper to roughen up the surface, i needed to apply paint


56.jpg

 

57.jpg


the first layer of base paint was ready 

58.jpg

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mrc4nl    0
the plexi arc (the front panel) needed a support:

59.jpg

i forgot there was a angle, now there is a gap

60.jpg

filling the gap is easy:

61.jpg

its a arc, and at a angle so the supports needed to be cut(miter?) in a special way 

62.jpg

add glue:63.jpg

a mount for the plexi

64.jpg

time to cut the plexi:

65.jpg

i also pained the bottom gray, but i am not satisfied by the result, ill guess ill make it black

 

time for another part: the top, its a special part since its the most visible one.

 

the shape consisist of a lage radius arc and two smaller arcs on the edges

the diameter of the big acr was to large for a single plank so id had to combine two.

66.jpg

drilling a hole:

67.jpg

fits nicely

68.jpg

i also needed to make room, so id could start milling

69.jpg

the workpiece is secured into position. i dont want any movements while milling

70.jpg

time to go milling:

71.jpg

halfway there:

72.jpg

the big radius was finished, so now i could mill the 2 smaller ones


73.jpg

 

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75.jpg


 

for visualising the size of the window i placed the motherboard on the wood

76.jpg

using wooden planks as guides for milling


77.jpg

 

78.jpg


done

79.jpg

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mrc4nl    0
I wanted to have the top of the desk a "quality" feeling.

 

Just made from wood, wouldt cut it (pun intended)

the top had to be made of a heavier and denser material: hard plastic.

80.jpg

small impurities from the wood are visible while milling.

81.jpg

dont mistake this for wood sawdust, it really is plastic!

82.jpg

i had to make spacers to keep the distance even

83.jpg

i put some holes in the plastic so i could screw the pieces in their temporarily place. movement is bad while milling 


84.jpg

 

85.jpg


i put some tape on the surface to make the milling a little bit smoother 

86.jpg

the front has been milled 

87.jpg

i hade to make my own guide for milling the sides.

88.jpg

outer shape looks fine:

89.jpg

even after dark i continued milling:


90.jpg

 

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still a little rough in the corners:

93.jpg

the 2 parts had to become one, so i did a little sanding:

94.jpg

put some paint,yes realy paint!! remember how sticky it is after 30 minutes and it has the right color


95.jpg

 

96.jpg


the paint was squeezed out by pressure:

97.jpg

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mrc4nl    0
Although i used paint to stick the 2 parts together, i also used screws. now the surface has holes.

98.jpg

Some polyester putty did the job of filling those holes. smooth when unmixed


99.jpg

 

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after sanding:

101.jpg

 

the edges of the desk were sharp, not confortable. there was a solution:


102.jpg

 

103.jpg


added some extra putty to hide the gap between layers

its starts to look good

104.jpg

borders are sticking out:


105.jpg

 

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some ledstrips to light up the inner desk part

108.jpg

looks realy nice

109.jpg

and i painted the top part shiny black

110.jpg

 

more ledstrips on the front:


111.jpg

 

112.jpg


heatshrinks 

113.jpg

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mrc4nl    0
making some aluminium panels for the sides


114.jpg

 

115.jpg

 

116.jpg

 

117.jpg


cross cuts for better removal of the inner material


118.jpg

 

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and glue it into place:

120.jpg

 

finally some industrial material: steel. i wanted to make my own motherboard tray

121.jpg

i had to bend it manually into shape, i had no machines to do it for me

122.jpg

the method is not that great, the radius is far too big

123.jpg

i did cut 2 planks at a angle, much better for bending sheets

124.jpg

cutting the IO shied holder


125.jpg

 

126.jpg


rough edges

127.jpg

and the second bend 

128.jpg

time for motherboard spacers, first i put tape on the surface for easy marking

129.jpg

punching the marks, for better drilling

130.jpg

tapping

131.jpg

motherboard fits

132.jpg

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mrc4nl    0
Thanks, taking pictures, post processing them in Lightroom, exporting, resizing uploading, writing urls. especialy writing the update takes a lot of time

 

i am running behind schedule for posting updates, because right now my desk is almost finished. i have a little catching up to do.

 

The motherboard tray was made, i was curious if the pc would still rune fine after 1/2 year being disassembled

133.jpg

the gpu is now upside down, in the final build it will be fan upwards. at least everything worked fine.

 

a little jump in time, i painted the wood desk parts white, it was time for the rear panel.things had to be cut to length, at least the height matched.

134.jpg

cutting the sides to length:

135.jpg

the top panel was a little to big though

136.jpg

thats better

137.jpg

 

the local glass store delived my 8mm hardend sheet.

138.jpg

i couldn't wait to see how it would fit

not perfect, but good enough, and its better to leave a small gap for temperature expansion anyway.

139.jpg

a quick assembly, with leds:


140.jpg

 

141.jpg


 

after the tray was in place i found out some cables were too short, for instance the gpu cable. i could buy a extension cable, but why not make my own? 

step 1 removing the insulation (i used a pair of scissors) 

142.jpg

wires are always stubborn when soldering, i used the scissors for keeping them together too.

143.jpg

the psu cable was a little longer now 

144.jpg

heatshrinks are important, a short circuit wont give any power to the psu.


145.jpg


 

a finished cable:

146.jpg

 

more electronics, I've bought some switches

147.jpg

4 holes had to be made

148.jpg

finding the center:

149.jpg

marking the margins

150.jpg

i also marked holes for the fan controller

151.jpg

some adjustments had to be made to make it fit

152.jpg

filling up the small gaps with filler

153.jpg

preparing the external cardreader for internal use

154.jpg

applying more filler

155.jpg

no more gaps 

156.jpg

the panel in white base coat:

157.jpg

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mrc4nl    0
its not that i am running out of time, its due exams at school i am late posting updates,

no more worklogs, just whats necessarily.

 

Current standing, a working desk although limited (no cardreader,water cooling, optical drive, or paint on the motherboard tray)

 

Before i made a entry i promised the mods not to show any work of 2012. i kept that promise. until now.the desk was never made to float in the air. The drawer parts complete the desk, the top sits on them, following the same

curves.Yes the desk itself can stand alone although that was never the intention. i hope this clairify's that and wont get me disqualified. (the drawers are a mere add-on)

 

 

maybe ill fix some problems and post other pics befor jan 31. but so now this is what i have:

 


158.jpg

 

159.jpg

 

160.jpg

 

161.jpg

 

162.jpg

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