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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:

48821489312_9f80c4b012_h.jpg_9292972 by greensabbath911, on Flickr

 

48821335056_8c3ed688c4_h.jpg_9292970 by greensabbath911, on Flickr

 

48821329656_dc0f67f0de_h.jpg_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:

48802440667_814fb47103_h.jpg_9262915 by greensabbath911, on Flickr

 

After:

48820990013_c8d3b440f8_h.jpg_9292940 by greensabbath911, on Flickr

 

More on this piece later.

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Posted (edited)

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:

48832248777_854693c7c4_h.jpgIMG_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:

48832248672_67378475fd_h.jpgIMG_6603 by greensabbath911, on Flickr

 

48831709553_4648941213_h.jpgIMG_6606 by greensabbath911, on Flickr

 

I put it over the top grill too:

48832248067_d7f123fa73_h.jpgIMG_6608 by greensabbath911, on Flickr

 

I also installed the LED strip into the top, making it ready to be put into the case:

48832247777_1968e98c7d_h.jpgIMG_6610 by greensabbath911, on Flickr

48832247617_bf26dbc205_h.jpgIMG_6611 by greensabbath911, on Flickr

 

48837329251_0ad48b57ba_h.jpg_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:

48831710528_64d42db860_h.jpgIMG_6596 by greensabbath911, on Flickr

 

And I cut the rest to fit from there:

48831710313_615bb1d4c7_h.jpgIMG_6598 by greensabbath911, on Flickr

 

48836960798_7f7c276579_h.jpg_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:

48831710003_646e6251d7_h.jpgIMG_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:

48832248962_119bee2a3d_h.jpgIMG_6600 by greensabbath911, on Flickr

 

The cover piece will look something like this and get bolted on:

48831710418_2257f0d1ae_h.jpgIMG_6597 by greensabbath911, on Flickr

 

48837507602_fe342beb66_h.jpg_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:

48840171028_ee906359b4_h.jpg_A030057 by greensabbath911, on Flickr

 

48840709747_41a39a2a85_h.jpg_A030047 by greensabbath911, on Flickr

 

 

Edited by Nicholas Falzone

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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:

48837503637_86e5301519_h.jpg_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:

48837503157_382d5146e7_h.jpg_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:

48837502107_fc2167a114_h.jpg_A020028 by greensabbath911, on Flickr

 

I cut it to length, gave it a miter and screwed it into the aluminum bracket:

48837502557_7bf01f4db3_h.jpg_A020027 by greensabbath911, on Flickr

 

48837326451_c727ec647d_h.jpg_A020029 by greensabbath911, on Flickr

 

Here it is installed in the case so far.  I'll be adding to this soon:

48837500617_96f8241b10_h.jpg_A020033 by greensabbath911, on Flickr

 

48837500237_c76067fd20_h.jpg_A020034 by greensabbath911, on Flickr

 

A bit more plumbing:

48840170798_f6006ef1b9_h.jpg_A030035 by greensabbath911, on Flickr

 

48840170613_0fb9fc28ee_h.jpg_A030037 by greensabbath911, on Flickr

 

A shot from the back:

48837325841_b8e52d2448_h.jpg_A020031 by greensabbath911, on Flickr

 

Edited by Nicholas Falzone

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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:

48840538386_208b63cf69_h.jpg_A030039 by greensabbath911, on Flickr

48840169928_59ab840b6e_h.jpg_A030041 by greensabbath911, on Flickr

48840710287_19a47618bc_h.jpg_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.

48840537396_c9ef9391e4_h.jpg_A030043 by greensabbath911, on Flickr

48840168878_2ec4652516_h.jpg_A030048 by greensabbath911, on Flickr

 

Starting the finishing pass:

48840709307_20c5720d97_h.jpg_A030050 by greensabbath911, on Flickr

48840536291_9c13ffb1da_h.jpg_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.

48840536081_b25294dca5_h.jpg_A030054 by greensabbath911, on Flickr

 

 

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Time for more watercooling plumbing.  I installed the processor and waterblock and started connecting the dots from there:

48869280527_25d9616bf4_h.jpg_A040059 by greensabbath911, on Flickr

 

48868562733_2abc83bbf9_h.jpg_A040062 by greensabbath911, on Flickr

 

48868556433_28a43b101f_h.jpg_A050113 by greensabbath911, on Flickr

 

48869078746_5f802bfbac_h.jpg_A050084 by greensabbath911, on Flickr

 

48869077221_43c0ff53b5_h.jpg_A050097 by greensabbath911, on Flickr

 

48869274422_0eccc3b865_h.jpg_A050108 by greensabbath911, on Flickr

 

Everything is mocked up at this point but not connected:

48869078061_f2373bfaa2_h.jpg_A050091 by greensabbath911, on Flickr

 

After everything was finally connected, I got ready for leak testing:

48869273572_35691fb9ed_h.jpg_A050115 by greensabbath911, on Flickr

 

48869074136_bfbb12ca17_h.jpg_A060120 by greensabbath911, on Flickr

 

After a few issues were resolved, I had the loop filled and running properly:

48868555553_b683ffe568_h.jpg_A060121 by greensabbath911, on Flickr

 

Its finally coming together:

48868553793_a74ddb0673_h.jpg_A060130 by greensabbath911, on Flickr

 

Edited by Nicholas Falzone

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Back to the Power supply mounting and cover.  I had the power supply mounted so I could make the cover plate for the mount:

48868560083_8b2a670aae_h.jpg_A050087 by greensabbath911, on Flickr

 

48869278362_6a7a5fd1ef_h.jpg_A050078 by greensabbath911, on Flickr

 

I drilled out space for the bolt heads below to fit into:

48869079266_63d08b1260_h.jpg_A050079 by greensabbath911, on Flickr

 

Much cleaner than before:

48869278042_0a9709aa9d_h.jpg_A050081 by greensabbath911, on Flickr

 

48869078061_f2373bfaa2_h.jpg_A050091 by greensabbath911, on Flickr

 

The sharp corner on the GPU mount was bugging me so I decided to chamfer it:

Before:

48869276752_9d577bb748_h.jpg_A050093 by greensabbath911, on Flickr

 

After:

48869077376_b7f551b8af_h.jpg_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:

48869080311_d9f5f37096_h.jpg_A050069 by greensabbath911, on Flickr

 

48868561588_74713a68a1_h.jpg_A050071 by greensabbath911, on Flickr

 

Cut to fit:

48868561253_1c9c572cec_h.jpg_A050075 by greensabbath911, on Flickr

 

48868561128_2300e39335_h.jpg_A050076 by greensabbath911, on Flickr

 

With some finish on it:

48869272712_d4156c0bc0_h.jpg_A060122 by greensabbath911, on Flickr

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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:

48868553113_ba13cb02dd_h.jpg_A060134 by greensabbath911, on Flickr

 

Heres the sleeving I'll be using.  Silver and Black Teleios sleeving from Mainframe Customs:

48869269992_b5714ade03_h.jpg_A060136 by greensabbath911, on Flickr

 

Pins and tools:

48869071461_1575a6760d_h.jpg_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:

48869070741_28dab73210_h.jpg_A060141 by greensabbath911, on Flickr

 

48868552633_74b72c255a_h.jpg_A060138 by greensabbath911, on Flickr

 

The cpu power cable is all done:

48869070591_5243d54174_h.jpg_A060143 by greensabbath911, on Flickr

 

Working on the 14 pin cables for the GPU.  This is where the pinout becomes super important. 

48869268877_548fd25d4c_h.jpg_A060147 by greensabbath911, on Flickr

 

Half ish done:

48868551178_6b758a6fc7_h.jpg_A060152 by greensabbath911, on Flickr

 

Somehow I had screwed up my pinouts so I had my smarter than I wife redo them for me:

48868550803_0d92ae4d65_h.jpg_A060156 by greensabbath911, on Flickr

 

The pretty side of the cable is all done:

48868550898_5f9e07d61e_h.jpg_A060155 by greensabbath911, on Flickr

 

Trying to tame this rats nest of cables:

48868550293_bcb5b76851_h.jpg_A060159 by greensabbath911, on Flickr

 

GPU cables installed, Its looking pretty clean:

48869068181_5942225e2f_h.jpg_A060162 by greensabbath911, on Flickr

 

48869067996_85a6fcca60_h.jpg_A060163 by greensabbath911, on Flickr

 

The back however needs some more work:

48869067021_0d917d1473_h.jpg_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.

48869067751_dd2d8e1755_h.jpg_A070165 by greensabbath911, on Flickr

 

About 3 hours later, its all done:

48868548258_ef1caa3f22_h.jpg_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:

48869264167_d6776f1f18_h.jpg_A080181 by greensabbath911, on Flickr

 

48868546853_7d8daf8099_h.jpg_A080182 by greensabbath911, on Flickr

 

The case is built and ready for final photos:

48868547488_9739db53e2_h.jpg_A080178 by greensabbath911, on Flickr

48869066331_f63e354b1f_h.jpg_A080175 by greensabbath911, on Flickr

 

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I present to you the final photos for Morphosis:

48874268152_f2e75c4fa1_h.jpg_A090404-Edit by greensabbath911, on Flickr

 

48874267772_3761858904_h.jpg_A090407 by greensabbath911, on Flickr

 

48873538498_bd84957696_h.jpg_A090391 by greensabbath911, on Flickr

 

48874072441_e25d9537c0_h.jpg_A090401 by greensabbath911, on Flickr

 

48874072676_7aad4bd30a_h.jpg_A090400 by greensabbath911, on Flickr

 

48873539048_46e977645c_h.jpg_A090390-Edit by greensabbath911, on Flickr

 

48873539443_3e8e568d20_h.jpg_A090385 by greensabbath911, on Flickr

 

48874074486_d1aea3c4e6_h.jpg_A090376 by greensabbath911, on Flickr

 

48874270862_e1f0570052_h.jpg_A090374 by greensabbath911, on Flickr

 

48874075231_78fee8a6a8_h.jpg_A090370 by greensabbath911, on Flickr

 

48873541113_25d011de15_h.jpg_A090363-Edit by greensabbath911, on Flickr

 

 

 

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48873541383_c5d9eb6036_h.jpg_A090360 by greensabbath911, on Flickr

 

48874272222_3cc51dfda5_h.jpg_A090356 by greensabbath911, on Flickr

 

48873541963_22f3668c5e_h.jpg_A090355 by greensabbath911, on Flickr

 

48874272717_7bda6cd99b_h.jpg_A090353 by greensabbath911, on Flickr

 

48873542638_df4a4125d9_h.jpg_A090343-Edit by greensabbath911, on Flickr

 

48874077221_5727e92dd4_h.jpg_A090338 by greensabbath911, on Flickr

 

48874077516_283eeb60a0_h.jpg_A090337 by greensabbath911, on Flickr

 

48873543468_64176f8d66_h.jpg_A090336 by greensabbath911, on Flickr

 

48874274232_b395f78d42_h.jpg_A090331 by greensabbath911, on Flickr

 

48873544048_f715599436_h.jpg_A090321 by greensabbath911, on Flickr

 

48873544298_d85cdef1b9_h.jpg_A090318 by greensabbath911, on Flickr

 

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48873544618_e00945f9f3_h.jpg_A080314 by greensabbath911, on Flickr

 

48873544958_cfff49dae2_h.jpg_A080313 by greensabbath911, on Flickr

 

48874275847_cc0e9ccd88_h.jpg_A080309-Edit by greensabbath911, on Flickr

 

48873545883_c56b7b9950_h.jpg_A080308 by greensabbath911, on Flickr

 

48873549063_5b75fff376_h.jpg_A080306 by greensabbath911, on Flickr

 

48874280072_e5335b1ded_h.jpg_A080298 by greensabbath911, on Flickr

 

48874086721_d99e338acc_h.jpg_A080296 by greensabbath911, on Flickr

 

48874283962_364983eb67_h.jpg_A080292 by greensabbath911, on Flickr

 

48874285327_f8871631e0_h.jpg_A080290 by greensabbath911, on Flickr

 

48874091526_3618578e01_h.jpg_A080288 by greensabbath911, on Flickr

 

48873559028_8ea9237a37_h.jpg_A080287 by greensabbath911, on Flickr

 

48874290357_71fc2e25f3_h.jpg_A080286 by greensabbath911, on Flickr

 

48874098421_02a0ef9d80_h.jpg_A080275 by greensabbath911, on Flickr

 

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