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phinix

PHINIX NANO TOWER - Scratch Build - 2011 Casemod Competition

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phinix    0

Now, the pump stand...

Again, this was done in hands, with dremel and files. A LOT of work.. believe me...

Main idea was to make simple, light frame/stand for the pump with reservoir. I went with my old design from the Cube - the one with single radiator+hdd frame/stand, that means circle rods and plates.

So I gathered few pieces...

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Using circle aluminium rod I was going to make small "columns" for main aluminium plates, mounting them together with 40mm long screws.. SImple.. screw goes into the rod...

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I measured dimentions and drew them on alu sheet..

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Few minutes with a dremel in my hands and I got these..

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I love the deep of field of those 20mm 1.7 lens:)

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Rough cuts were going to be polished soon...

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Quick mockup without screws and holes:)

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..and ready product.. first piece of course...

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Pump will be mounted on it with velcro pads to reduce vibrations

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..and the stand in the Tower...

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Now, let me explain the whole idea. This is just a first piece of the full stand. What will come next?

This is going to be interesting, I can tell :D

The WHOLE idea came out from the way I am going to build the water cooling loop for graphic card. How? Here you go: I need to make it easy to install / de-install, so I need easy access to the whole loop. It is "impossible" to fit hands in this small Tower case and disable the loop without making a mess and disaster, right? Right.. but not exactly:)

I am going to use quick release fittings sets in two places: before GPU block and right after GPU block. Both sets will be easily accesible in the left side of the case, right behind the left window. Why do I need them? Because I have such a small space to manouver with the loop, so I have to make it in one non-flexible loop. That means I won't be able to get to the every single compression fitting in the loop without draining it, BUT to resolve this issue I will be able to disconnect graphic card (block) from the rest of the loop: pump, reservoir and huge radiator! Isn't that great? :D

All those items - pump with reservoir and radiator will be built in one fixed piece. With three easy moves I will be able to take all loop out without making a mess - this design is very hard to achieve, believe me, I was planning it for a last 2 months...

So 3 simple moves will be : taking the left panel away, disconnecting two sets of quick-release connectors and taking the rear panel away! :D

Now, last explanation - pump with the whole stand and a piece of the top power chamber panel will be mounted together to the bottom of the rear panel, right between the inlet and outlet!!! Yes, all in one piece!!!

Take a look on the sketchup with the pump stand and the piece that attach it to the rear panel.

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Now, this is the top panel of power chamber. It is cut in the middle (actually I will cut a bit less, like a rear left corner so I could pull it out from the case from the back of it)

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This is how it goes in the left panel of power chamber - it slides between top edge of that left panel and L shape aluminium profile corner on top of them.

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This sketch shows how it goes in the case. You can see ther two "go-through" adapters that will have two quick-release fittings sets screwed to it. So, when I'm going to install it, I will push the whole combo in and screw in the rear case panel, then simply connect quick-release fittings together with sticking two tubes form the gpu block.

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Here you can see how it looks from below - you can see the pump stand with that long alu "arm" that goes up to the top panel - that is how the rear piece of top panel will be mounted to the whole pump stand. I will also cut small piece of yellow acrylic to fill out that gap between two pieces of the top panel and light it up with yellow leds. Acrylic will also go with the whole thing outside to the rear of the case.

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...and last image: shows how it goes out the case. Mind there is no rear main case panel there - it will be screwed to that small L shape on the bottom of the pump stand.

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...and here in the case...

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That's it. Mistery solved:) I hope you like the idea of how I'm going to solve the tight water loop problem:) I think it will work great. Well, in this kind of small case there is no other way to do it actually. There is no space to let me get my hands in and unscrew fittings or any other way to dismantle the whole thing.

I'm not an expert in Google Sketchup tube drawing, but I spent a bit of time on trying to visualise how the tubing will run in the Tower. Just two simple sketches to show how it will work...

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Of course there will be two sets of quick-release fittings installed on top of that power chamber panel, but didn't draw them.

So, I basically made exactly what I planned on sketches, added bottom plate which contains small piece that bolts the stand to the rear panel right under the radiator, long vertical piece to mount one piece of power chamber top panel to the stand.

Here's how it looks right now:)

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"Head" of this thing goes right up to the surface of power chamber:

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This is how it looks inside of the Tower:

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To make it all right I had to trim that L shape alu profile on the right from the pump stand. I trimmed it on the whole length cause it didn't look "nice" when I only cut out small piece at the bottom, where the tubing will go from the top to the right radiator inlet.

Well, to make it short - it's like I wanted:)

Now, I decided to go with fluorescent yellow - Helios - color acrylic. It looks like that:

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This piece goes under that smaller piece of power chamber top panel.

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It will have that two pieces of aluminium on top, leaving small gap, where yellow acrylic will be light up with leds.

I added one small detail - one more cut line in it to make it more interesting:)

This is how I planned it on sketches:

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..and this is the execution:)

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..here added that L shape profile that will cover "contacting edge". Left side cut out - this is where the reservoir will stick out alter on...

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Here how it looks inside the Tower:

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Second thing is fan controller.

Tricky part was to squeeze it between right square rod and radiator fan that will come on left...

I measured it up 3 times.. and drilled the holes.. all came out PERFECT! :D

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Now, bottom acrylic panel. 10mm thick stuff!!! My dremmel sweat like a strongman cutting this thing. After 10 minutes operation PSU hole was finished...

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Now, another thing - I decided to use two switches for internal lights and front panel. I'm using white led switches.

Measuring, sketching, drilling and a looooooot of filing:)

They will be attached on right side of the case, bottom part of the rear panel.

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What I also did is I cut to size round mesh for cover that I'm going to paint and install on rear radiator.

Here's the radiator that I will be using - EK triple XT:

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...and here is the mesh cut to size and on the radiator...

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It will be screwed with small M3 black cap head bolts.

I don't have any idea yet how I'm going to paint this mesh, but I think it will be some kind of hex shape pattern.

Next thing - side panels.

Basically what I did was I measured up and drilled holes for rivets in side panels. It was pretty hard, cause the holes had to be in exact same place on top cover and main panel, so I spent few extra minutes to make sure holes are all align perfectly... To be honest I hate this kind of job cause there is no second chance, if you screw it up, you need to cut new panel... :cry:

But it all went well, I didn't have to re-drill any of the holes so they are all fine:)

First I marked holes on top cover, then drilled them. After that I aligned covers on side panel and started making marks in the drilled holes...

Here it is, top covers landed on side panel... pen in my hand.. no breathing.. steady... point.

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This one here is the side panel screw hole, one hole on each panel ended up half uncovered, so I will have to file a nice hole around it, hex shape hole, to match the theme. Rest of the holes are under covers, so I just drilled them through.

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I attached covers with small M3 screws for now to keep them together.

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All holes drilled and cleaned...

Last thing tonight - some water cooling compression fittings show! :)

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Of course I couldn't resist to unpack every one of them, so here it is...money shots:D

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This one will go to pump outlet...

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..two of these will go to radiator

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These two will be mounted in top power chamber panel and will route the tubing to the graphic card block...

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These two will help redirect the tubing with quick-release fittings to go around the reservoir...

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This is beautiful water temp thermometer which will be installed in one of the reservoir holes, then to nice temperature gauge...

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phinix    0

Time for another update.

Top panel.

It is made of clear acrylic, 10mm thick piece of plastic :shock: If you don't have router or laser cutter and all you have is dremel with small cutting wheels, then your work with 10mm thick acrylic will be full of pain, sweat and tears :shock:

But, after few hours spent on this I finished it and pretty happy with the result.

Basically after painful cutting holes for dvd and top fan, I measured and drilled 4 holes for top aluminum cover. Of course I used my famous threaded insert + soldering iron trick for mounts.

After few minutes with hot solder iron tip, I had this:)

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Threaded inserts in the hole!

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I know, dvd holes i a bit "funky" in left top corner, but no worries, it will be covered with dvd aluminium cover. Like this:)

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If you noticed, there are black lines drew on each corner - that is where I needed to file this acrylic panel.

Corners of the NanoTower will be cut off and flat, not sharp like regular square.

Now, I had an idea how I'm going to light up the top panel, even for a bit, so here it is: I fabricated small yellow acrylic piece that will go under the top panel. It has longer corners for mounting holes.

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Also cut out small piece of mesh, which will cover the hole in top panel. Its a bit dirty on that photo but its after drilling in acrylic, acrylic powder was everywhere :D

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This is how they both go under the panel. You can also see I had to cut out more acrylic on both sides for power button and USB socket.

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Here are few photos with sun light going through it...

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Then I drilled and using small M3 button head screws I mounted mesh, yellow acrylic piece to the top aluminium cover panel, so it looks like this.

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This acrylic panel will be spray painted matte black when the other bit will be done.

I came up on a small problem, but solved it quickly.

Both, top and bottom acrylic panels supposed to touch top and bottom aluminium panels, but there were M6 screws on its way on each corner. I don't really wanted to cut out holes in acrylic to hide those screw heads. So I ordered some countersink screws...

Problem....

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Solution...

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Result...

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Nice and clean, exactly as I wanted it to be.

Now, I decided to re-do my motherboard tray, now it looks liek this:

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Next, I finished all mountings for power chamber.

I had this L shape alu profile, so cut out small piece, cut off 1cm along the edge so it would fit in next to the acrylic piece under power chamber top panel and riveted it to the sides.

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Here, those two screws are holding top panel. If I need to take off top panel, I simply unscrew them with hand. Easy peasy...:thumb:

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Now last thing I did lately. I finally mounted top acrylic panel to the Tower.

I changed the idea of using some locker kits and decided to use two screws that I can unscrew by hand. Easiest way possible.

I drilled and threaded holes in top aluminium panel...

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Both sides...

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Then I drilled holes in top acrylic/alu combo panel...

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..and added two screws. Job done:clap:

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As you can se below, screw goes easily through the acrylic panel to the aluminium frame under it where the hole is tapped. I like this solution.

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NanoTower with finished power chamber and properly mounted acrylic top panel.

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phinix    0

Here are photos of some items - water cooling bits.

First, fantastic quick connectors:

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Now, these are small 2 pin connector I'm going to use with all led lighting strips. These will make taking case apart much pleasent.

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Now, SMD yellow led strip - 4 meters!!! Also some UV leds, cable and huge banch of 3mm yellow leds:

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Here's two photos shows the tube I bought - yes, this is orange, yes it is not yellow. Let me explain - yellow tube under UV light looks like... acid-green. This orange tube under UV light looks like... sweet deep yellow. That is why I will use orange tube to get nice yellow effect. You will see, it will be fantastic!... Well.. I hope... :eeek::worried:

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Now, I've noticed a small "glitch" with power chamber top panel acrylic piece - I used two small screws to keep it together, but one of the ends was sticking out a bit. This end was to thin to drill a hole in it, so I had to re-do this acrylic bit that goes under top panel of power chamber.

Without any more words, here is a new revision of this piece:)

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It goes under the panel in this position.

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It was time to give attention to side panels and their decoration bits:)

These here are long 5mm strips of black tinted acrylic.

I cut them up to small 10mm pieces and will use them as separators in side acrylic "combs".

Second photo shows those long strips next to those pieces.

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Here is one "mockup" comb, I built it to show you how they going to look like. Mind there is still white cover foil on them, which I wanted to keep till I actually glue them all together.

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Second thing I made from black tinted acrylic are 4 corners. Sounds strange, but here's what it is: each corner of rear panel will have black cover which will be screwed to the panel and will also be a base for six L-shape yellow acrylic elements. Those elements will create those corner "combs", as you could see previousy on some of my sketchups. Acrylic corners are screwed with one M4 screw that keeps the rear panel to the frame and two smaller M3 screws that hold those corners mounted to the panel.

Here are few shots showing them, first - whole panel, second and third - bottom and top corner...

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...and here is rear panel with that black corner, standing sticked to the "mock-up" comb:)

It looks great in reality, better than on photo, believe me:) I can imagine it will look even better when the panel will be coated and that comb glued...

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Another day of work...

I had to measure and install standoffs for my little mobo, so "tried on" my mobo tray...

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You can see it fits nicely, not too tight or anything:)

To make points for standoffs I used a match and hand cream:)

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Also, here you can see how the pci-e slot goes along the line of power chamber.

Graphics card will be about 2mm from the panel.

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phinix    0

I had to "trim" two of all four columns in main frame. Why? I noticed a bit difference between them and when I installed acrylic 10mm thick bottom panel I noticed this sucker started to shake a bit. I don't know how I haven't noticed that before, but looks like 0,8mm difference between two columns made a huge impact on stability of the whole Tower.

10 minutes with file and sand paper put it all down and Tower become stable as a rock:thumb:

Now even all panels lined up better than before. So it looks really good, almost perfect;)

I love to put on all panels and look on corners, they look so cool:)

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This one here, rear left has to be modified cause this is the corner where I'm going to cut out long hole for peripherals cables, like graphics card cable, usb, etc.

That is why I had to use one more screw on the top of it, cuase lower one will be cut off...

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This is the corner where you can see I drew the hole that will be cut out.

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And just a few photos of all 4 panels installed on "naked" frame...

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..last photo.. I love that "dramatic" filter in my camera... Tower coming out from the darkness....

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I got more bits cut out on CNC - they had to be perfect so couldn't do it in hands.

First thing after I received the package, I unpacked it all and took it to the bathroom to clean it up. I gently took off the protective film and washed every single piece, then dried it one bath's edge. Even with lights turned off, all acrylic pieces looked amazing... So here they are...

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Lots of shiny bits:) Some will build a nice reservoir cover for my "viewing chamber", so will be used for front panel...

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After few days here is another update!

First, top piece of "power chamber" - I made this small change before and used this new piece of acrylic that I showed before. It looked nice after I mounted it.

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However, I was thinking about it and realised that I may have problem with it, after I install quick-release connectors. I needed another change in plans - problem was, those quick-release connectors need a bit of force to be plugged in. I had a feeling that pump stand is not strong enough to keep the pressure on the top piece when plugging those connectors.

So I had new idea how to solve this:)

I added second long piece of alu to hold top cover.

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Then I realised that this nice yellow acrylic under the top cover will look nice only when removable piece from pump stand will be perfectly aligned. And that could be very hard every time I put rear main panel back with the pump stand into the Tower. It could be always uneven, looking odd. So decided that this thin long gap with yellow acrylic will be permanent.

I had to trim one piece of cover to make space for reservoir and third smaller cover that will be screwed to those two long aluminium supports. This third piece would be "mobile" and match the shape of the second "not moveable" piece.

Well.. see it yourself, cause its hard to explain;)

This is the final version of the pump stand with third smallest alu cover-piece...

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I screwed it to those two long supports... using all my nuts:blush:

I need to buy some more...

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Here is the whole thing - you can see three top cover pieces, two screwed together with middle acrylic piece, and third one, the one that comes with pump stand.

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It looks pretty cool, now imagine it will all be painted black, so those edges will be less visible and all will look nice:)

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I bought this nice anti-vibration foam and cut it to size for the pump.

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Looks pretty cool...

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Look what a mess I made in my attic :shock: My wife wasn't happy after she saw it :oops:

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My new invention - I mounted vice on my drill press:D

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What I also did is I cut out hole for PSU and CPU cable in top power chamber panel and put some edge rubber cover, or whatever its called...

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Other thing was to cut out some of the aluminium from top panel for power switch and USB socket. Old fashion drilling action:)

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Final result - fits perfectly:)

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I also made a nice support for leds under top panel - simple and functional.

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I also have made a cover for hole in left panel of power chamber - this is where GPU power cables will come out and pump will have its outlet connected to radiator. It also covers cables to led switches in the rear panel.

This is a first stage of it, not finished yet, I'm only showing you the idea how it will be mounted...

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I also bought a nice yellow temperature lcd monitor-display...

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Last thing - I drilled and installed cable holders - this is where GPU power cables will come out from the power chamber, so they must be held in place...

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And for the end something nice to show - please have in mind this is only a mock-up:)

I just pushed those rings into this one support, it all looks wobbly and uneven, but.... I loved the look of it, so wanted to share:)

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That is all. I hope you like this update and please stay tuned for next time!!!:rock:

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phinix    0

Happy Easter everybody!

I found a time to add another update today.

Next made pieces were those acrylic combs. Glued all pieces with pretty good glue for plastics, Tensol 12.

Every single L shape was glued with small 5mm long black tinted acrylic rectangle.

Here's how they look:

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Here is the Nano Tower during "the glueing procedure":)

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Then it was time to send all aluminium parts to powder coat place.

I took all apart and flat packed it.

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However, before I sent it I had to make "last holes" in some panels.

Here's how I was preparing front panel for drilling holes for leds. First I had to place hex shapes in a pattern I designed it in the past.

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Those aluminium hex shapes need to be painted first, then glued to acrylic ones, then to front panel...

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Here's front panel cover - beautiful..

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..again, two shots of acrylic combs on front panel....

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First comes main front panel, then acrylic piece...

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I made dots in places of acrylic hex shapes to drill holes for leds...

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Then I drew lines in holes in top cover to see where I need to drill holes for leds again...

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..and aligned led strips to make marks for holes...

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..and here how it's going to look like under the panel:) As you can see, led strips will be under the main panel cover so you won't see leds it selves, they will light up the panel right next to every edge. I think it will add a nice touch to the front panel.

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... holes drilled.. like a Swiss cheese:)

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Those 72 holes for leds that come under the combs was the hardest part...

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Cage had to be modded for this part in left bottom corner comb...

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Last photo - Mobo's I/O panel - middle one in the Tower - also had to be finished before I sent it to powder coat. I cut out those big holes for mobo and graphics card. Also added long thin hole for graphics card back frame.

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phinix    0

After few weeks I received my Tower bits powder coated.

It was all beautiful, I had to take picture of every single bit:)

I played a bit with light to see how front panel will look when lit up with leds.... See yourself guys, Colours look really nice.

All main pieces were coated satin black, where 3 main panels - side ones and front were coated dark grey - very similar to satin black but still a bit lighter to show the difference of those top cover bits.

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phinix    0
A very small mod but very big on work and detail 8)

Thanks, I'm glad you like it! :cheers:

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