Worklog: Lian Li PC70 - watercooled (old worklog)

[wilchelus]

Well, after 5 years I thought I would finally post up the worklog I had created whilst building the water cooled machine that I still use today.

This is going to be a rather long post. Hopefully you guys won't mind that it's so old. I just had the urge to share is all.

Please bear with me while I post all the stages I went through.


2 June 2002

This project began in March 2001. After many different phases/plans we were finally able to settle on a basic design that used the Lian-Li PC70 all aluminum full tower case.

The original design involved the Lian-Li PC60 mid-tower case, but this was before we settled on watercooling. The original system involved many fans spinning at high RPM and pushing many CFM of air through the case to keep everything cool. Basically we were going to be creating a very loud and high pitched wind tunnel that would sit at our feet. A fast and "pretty" computer but also a very loud and annoying one.

After mulling over a few idea's we decided on watercooling. The aim was to create a watercooled PC that had no external components (other than the usual mouse, keyboard, monitor, etc.). The watercooling system had to be contained within the case. Unfortunately the PC60 was too small, yet we had already purchased 2 of these cases. So these had to be sold off, and the PC-70's were ordered, shipped, and delivered to us within the month.

The project stagnated for awhile as the "necessary" components had to be ordered. Some of which are still on order.

Danger Den's waterblocks, Super Cube radiator, and the Eheim 1250 were chosen as the main watercooling components. The PSU we decided on was the Enermax EG651P-VE.




Since we had most of the gear that we needed we decided to make a start on the case modding.

First on the agenda was to strip the case bare. Remove all panel's, switches, and bay's. The removal of the roof required drilling of those awful rivets.

Please excuse the "photo's-of-photo's", only a few will be like this. I didn't have a digital camera at the time)




Next, cut the hole in the side of the case for the plexi-glass window. The process was rather tedious, but easy. It involved drawing the design on the side panel of the case, drilling at 5 particular points, using a nibbler tool, and then using a jigsaw to cut the straight lines.




Lian-Li PC70's unfortunately are not "Enermax friendly". The only way to keep the case chasis unchanged was to install the enermax PSU upside down, with it's internal fan pointing up at where the radiator was going to be. So we got to the cutting and chopped up the inside of the case aswell. We used the nibbler ofcourse.



As you can see the bottom "shelf" was cut to accommodate the fan.



This was not all that needed to be modified for the PSU. We also had to manufacture our own backplates as the standard ones had the mounting holes for the PSU in the wrong place, and had provisions for 2 90mm fans where-as we only wanted 1 120mm fan above the PSU.


The original rear backplate is in the middle, flanked by Corey's and my new backplates.

And here's the finished product (radiator is already mounted in this pic)

[wilchelus]

The next problem to tackle was how the hell do we mount the radiator above the PSU. We found that after the 2 120mm sunon's had been fitted to the radiator the unit was very heavy. Remembering that this will also have to hold water we decided to mount the radiator using alluminium brackets attached to the top of the chasis of the case.


Here you can see the bracket.


The right most holes had to be drilled and counter sunk, the 2 left most were already there (thankyou Lian-Li)



Here is what the cases look like with the radiator's, and PSU's fitted:



and with the top on

[wilchelus]

Now to get cool air to come flow through the radiator another plan was hatched. Let's grab the air from the top of the case to blow through the radiator and out the back. How were we going to do it? Plexi, 90 degree PVC pipe, and a nice laser cut fan grill.




We had to cut this pipe with a hacksaw to get rid of the stupid "pipe" ends, then attach some plexi with araldite and silicone so that we could mount it to the fans.


mounted.


where the fan grill is going to go and basically where the hole is going to be



all measured up, protected with masking tape and ready to cut.

[wilchelus]

During this radiator fitment time the cold cathode tubes that we had ordered had arrived. So we decided to plug them in and test. The idea is, we are going to have the blue CC attached along the bottom of the window on the door, and the red CC running up the front side of the window. The blue CC will always be on while the red will trigger whenever there is a loud noise.

[wilchelus]

Now to the bit which wasn't supposed to be hard....Now I say this because really it shouldn't have been that hard to do. But no. We had to fuck up now didn't we. Both of us. The problem started with these stupid switches that we bought from Jaycar. They require a hole approx. 16mm in diameter. Now, if you know drills, and drill bits you know that usually the max a "normal" chuck can hold is 10mm, and a 10mm drill bit is large...not huge...but large. To cut a long story short we went the "cheap" route and got a 16mm wood drill bit. BAD IDEA. Anyway, let's let the pictures do the talking.


this is where the temperature LCD's and buttons were going to go




The drawing and final design stage



ARGGGHHHH!!! FU(K!!!!! S#IT!!! CRAP!!!!!!!!! POOO BUM WEE!!!!!!

[taztassio]

looking good mate, like to see the end product!

[wilchelus]

We had to come up with a new plan...Well for the side of my case anyway. I decided that the only option was to move both far side button's out further by a few mill, and instead of using that stupid drill bit use my trusty old nibbler and make 16x16 square holes. Meanwhile, while I was busily re-measuring Corey started to nibble his holes out.....OUT TO 18MM!!!!!! By the time I asked him if he'd measured the 16 it was too late. We had both totally forgotten about the fact that the current measurements were to 18x18 in the whole "scratched the f'ing side panel incident".

Bugger...

Another plan was hatched. Create a recessed "control panel". This involves cutting out a large area of the side panel which meant that our stuff ups would be removed.

To create the recessed control panel's we used some scrap alluminium left over from when we cut the main window holes from our case sides. Re-designing, sketching and cutting followed.


Here is the new plate in the process of being made. You can just make out the rectangular section that will but cut from this piece. (this is the reverse side of the alluminium).

Below is the other side, masked off for protection ofcourse.




These panel's will be cut down to size.. You can see the pencil sketches on one of the pictures above of basically where the panel will be cut from. This will then be mounted to the rear of the case's side panel with the use of 3mm alluminium spacers which will in effect recess this panel and keep the buttons, and LCD's away from any damage. So far this is all that has been done. More to come.

[wilchelus]

9 June 2002

Ok, here I am at the end of the 9th June 2002 at approx 5:44pm. Today Corey and I managed to finish off quite a bit. Everything is going as planned, and fortunately there were no stuff ups today.




Plan of attack:

* Re-draw the measurements for our "sunken" control panels on the sides of our cases.
* File down the holes to ensure that the LCD's and buttons fit.
* Cut out the new holes in the sides of the cases.
* Cut out the 120mm circular holes on the top of the cases for our vent.



First off, draw the measurements on the side's of the cases. 14x9mm.





As you can see in the photo's the old marks and the stuffed up cut with scratch are still there. The new darker lines is where I'm going to cut.



All nice and straight. The "FUXUP" is now gone. Hmmm... two big holes in the side of the case.

[wilchelus]

Now to filing the holes on the new control panel to ensure the LCD's and buttons fit nice and snug.



Mmmmm...nice and *tight*

[wilchelus]

Now to a part of this case modding saga that I had been dreading. What I really wanted was to buy a 120mm hole saw. None could be found at a reasonable price. The closest thing we could get was a 110mm cheapy, that would last 2 cuts, BUT is too small. I settled after much deliberation on using the trusty old jigsaw.

The jigsaw has been used a helluva lot throughout this project. Nearly every cut we've done has been done using the Bosh jigsaw. I remember reading about using people using a dremel to case mod. No F'ing way! We have a dremel, but the large cuts would just take too long, and straightness...well is something to be "hoped for" rather than something that happens. Sure, getting this straight with a jigsaw is also hard, but is very do-able. Just look see how straight the sides of our cases have turned out.

Anyway, back to the top of the case. For a run-down on "the plan" and design stage click here and scroll a little bit more than half-way down.





Here we go. First off I drilled through in the corner with a large'ish drill bit and used the nibbler to cut out to the edge of the circle. This made a hole big enough for the jigsaw's blade to fit in. Then to the cutting. Time and patience, time and patience, that's all it took.



Yay! All done. Here I've placed the laser cut grill on top of the hole. The masking tape on the top still remains as tomorrow I have to drill out those four nice little holes, which I'm sure will be a pain to do. After that I have to drill through into the top plate of the 90 degree PVC pipe that I made so that the screw's will go through....I'm positive this will be fiddly.

[wilchelus]

10 June 2002

Here come the fiddly bits.

Plan:

* Drill the holes on the top of the case for the laser cut fan grill.
* Drill the holes on the top part of the intake pipes mounting bracket.
* Put the intake pipe on, put the filter on the top of the intake pipe, put the top of the case back on the case, put the laser cut fan grill ontop of this, put the 4 screws through and pray that everything fits together nicely.

To drill these holes through the top first up I positioned the laser cut fan grill on the top of the case making sure that the holes lined up with the marks that I had drawn on previously. Sure enough all but one fit. grrr... But all was fine. Next up I marked the middle position of each hole with a hammer and nail, then drilled through.



Came up pretty nice. The grill is in the middle, and all four screws fall through straight.






Now onto the bit which I had been dreading. Drilling the mounting holes through the mounting bracket of the intake pipe so that they match up with these ones.

[wilchelus]

Mounting the intake pipes back onto the cases was up next. Easy, but fiddly nonetheless with the nuts and the screws...





All nice and snug. If you notice I blocked up the fan with masking tape so that no bits of metal or plastic could get in the fan and be blown through the radiator later on.

The plan. Both of us were undecided on what to do. Personally, I wanted to put the top on, use a tiny drill bit, drill small holes in the "relative" centre of the holes in the top of the case, remove the pipe, and drill out these small holes with a larger bit. Corey on the other hand had different thoughts. He believed it would be better to just do it in one hit. Top on, 4mm bit, drill through the top holes and down into the pipe. I conceded...thought, "eh, give it a go". Anyway this is what happened,




The plastic mounting bracket we made went "snap". So we tried my plan on my case.





Drill through the top holes with a small bit down into the mounting bracket, remove pipe, and re-drill with larger bit.

Worked a treat!



I've put the fan grill directly on the pipe to ensure it fit nice and snug. We had a few drama's with Corey's one however. Involved a bit more drilling and mucking about, but his fits now too. Onto putting the top back on and seeing if everything still fits.

[wilchelus]

All went well. The top went on, the grill went on, and all four screws went through without any problems.



..and with the filter in place under the grill



Now to get rid of that masking tape.



Hmmm..sticky. And here come the pics without the tape.

[wilchelus]

A good days work.

[wilchelus]

6-9 July 2002

This one's a small update. Haven't really done that much since the last update. Now I'm basically just getting the new control panel sorted with it's electro luminescent cabling, and some clear trim to hide the stuff.

On with the pictures.



Ok. On the left we can see that "clear trim" that I was talking about. Basically, the electro luminescent cable will shine through this.


And here's the cut control panel without anything installed on it yet.


Here's what the electro luminescent cable looks like. Looks snazy when it's turned on.



Yeah, yeah, it's too long. It will be cut. But I'll trial fit it first before cutting.
Now onto sticking those clear pieces on. Alluminium to plastic. Hmmmm......