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Project: Big Loud Server

Discussion in 'Modding Worklogs' started by crazylittleman, Aug 6, 2006.

  1. crazylittleman

    crazylittleman Member

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    Project:Big Loud Server (100% completeish)

    Hey all.

    I've been a long time reader I've this here modding forum and it has inspired me to build my own case plus i just wanted to kill some time. Anyhoo i came up with the original design a few months ago and there is some discussion in this thread and as a result i made a few changes.
    This is the final design.
    [​IMG][​IMG]
    The total dimentions are 450x230x580 (L x W x H). All the panels will be chequerplate aluminium and the area marked in blue will be a meshX type vent. The internal frame is made from L bracket aluminium then joined with pop rivets and Araldite. The front 4 intake fans and the top exhaust fan are 120mm and the 2 rear exhaust fans are 92mm.
    Both PSUs are supported by the rear panel.

    To date construction consists of the aluminium for the base measured and cut.

    [​IMG]


    Thats about all until i find out where i can get chequerplate to finish the base.

    Any and all comments welcome except if they are about how I'm wasting my time and i should go by a stacker.
     
    Last edited: Mar 1, 2007
  2. Stygian Shane

    Stygian Shane Member

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    Hope you've got lots of money. Chequerplate is EXPENSIVE, and unless you go through a DEVILISH amount of planning, some of the rivets are going to be sitting on top the the peaks in the chequerplate. Tis fun to try and countersink those, without making the hole too big for whatever is securing the panel.
    Having said that... looks promising.
     
  3. OP
    OP
    crazylittleman

    crazylittleman Member

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    Yeah i had a look in Bunnings the other day and it was something like $77 for one sheet of chequerplate but im hopeing if i got to a specialist aluminium place i can get it for less.
     
  4. brodsta

    brodsta Member

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    Yeah bunnings isn't cheap for any sheeting/wood supplies. They can charge more because they pretty much have everything in the store. A metal shop should be able to give you a better quote than that, but regardless of where you go, chequerplate is exy.
     
  5. swamprat

    swamprat Member

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    by exy i asume you mean sexy. chequerplate rubs me the right way :D
     
  6. brodsta

    brodsta Member

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    By exy I meant expensive, but I agree with your statement. :D
     
  7. OP
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    crazylittleman

    crazylittleman Member

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    Update.

    Modding contiuned I've cut, glued and riveted the basic frame for the top of the case. It all went to plan besides a few crappy rivets that would rivet properly but other then that all good.
    [​IMG][​IMG][​IMG]
    Due to my lazyness and the complexity of the corner joins its slow work.
     
    Last edited: Aug 26, 2006
  8. OP
    OP
    crazylittleman

    crazylittleman Member

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    Hard Drive Supports

    [​IMG]

    Quick design change the hard drives will now be supported on rails made from the same L rail as the rest of the case. The drives will secure via screws from underneath. The idea is to put together all the supports for the hard drives so they can be place into the frame as one unit. The first step is to cut all 28 support rails then drill the holes to secure the drives. The holes are drilled with the aid of a wooden template.
    [​IMG][​IMG][​IMG]


    Next the support rails have to be riveted to the upright supports. I did this by cutting correctly spaced grooves into a block of wood the clamping then uprights into the block. This allows me to easily place the support rails to be drilled with a hand drill. I then glued and riveted 3 of the support rails to keep the whole load square before I try and drill the rest of the holes.
    [​IMG][​IMG]


    One completed set of supports for hard drives. Took about 90 minutes of drilling and riveting.
    [​IMG]

    The next step is to put together the second set of supports. The difficulty with this is that each horizontal rail has to be at the exact height of its pair on the 1st set of supports. So the easiest way to do this is to clamp both sets of supports together and just line them up. Like so.....
    [​IMG]
     
  9. Mad 4 Air

    Mad 4 Air Member

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    How is it you will screw the hdd's in when you've got the support rails riveted in and so little space between them?
     
  10. OP
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    crazylittleman

    crazylittleman Member

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    There is enough space to screw in the drives with a small right angled screw driver. Theres about 35mm between each support.
     
  11. Mad 4 Air

    Mad 4 Air Member

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    Cool. Nice idea aside from checkerplate. I'm really not a fan (of checkerplate). I'm looking to design a new housing for my file server that i will find easier to work in. I'll watch how you go with the L shaped aluminium.

    Will you be making up a mobo tray and backplate etc or just gutting a case for them?

    BTW, should just get a stacker ;) :Pirate:
     
  12. OP
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    crazylittleman

    crazylittleman Member

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    I'm just getting a mobo tray from my current atx case.
     
  13. DeNs

    DeNs Member

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    Not to knock on your idea, 'cause I do like it a lot, but why not just get some sheet aluminium and use that rather than checkerplate?

    Am I the only one that really hates how it looks with modding? I've always felt it belongs under your feet on walkways rather than on a case. Maybe it's just me. However I can think of many things you could do with just plain sheet aluminium rather over checkerplate.

    Looking forward to the final result :)

    ---dens
     
  14. OP
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    crazylittleman

    crazylittleman Member

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    I think if chequerplate is polished up well it looks really good. But thats just my preference.
     
  15. MrSmith

    MrSmith Member

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    Wow, that's pretty amazing!

    Won't heat be a bit of a problem with those drives (13?), Are you planning on using some Master Blasta style 12cm 240v fans at the front with some rocker switches? That'd be mad!

    Keep up the good work.. I'll definately follow this.
     
  16. Mad 4 Air

    Mad 4 Air Member

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    Not really sure there would be much point to mains powered fans when he'll be running dual psu's anyway. If your looking to get some 12v 120mm look at the scythe s-flex at d & ke while they're closing. $20 each instead of $30 and they are quality units. I'm using the 20dba versions on my rad at the moment but since they are only for hdd cooling you could go the 8dba units. I guess it then wouldn't be such a big *loud* server though ;)
     
  17. OP
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    crazylittleman

    crazylittleman Member

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    Minor Update

    [​IMG]

    All the panels arrived today. It ended up costing $95 for all of them.

    Construction Error
    At some point during the construction of the top section of the frame I wasn't paying attention and I made a rather large error.
    [​IMG]
    (looking down at the bottom of the top)
    The original idea was to have a 63mm gap on the right side of the case to hide all the cabling in. But for the above said reasons I have ended up with the 63mm gap on the left.
    I cut out most of the L rail with a hacksaw just leaving the two ends glued down. Then I drilled out the rivets and drilled away as much of the remaining aluminum as possible.
    [​IMG]
    Then I cut away as much of it as possible with a Dremel, the Dremel discs i was using were those $20 a set generic crappy ones so it wasn’t really effective at cutting but it did generate enough heat to just melt away the remaining glue.
    [​IMG][​IMG]
    That was the method i used to remove the 1st 2 joins, the 2nd 2 after i drilled out the rivets then just hit them with a hammer and they came loose.
    [​IMG]
    Finished refitting the cross pieces in the correct position.
     
    Last edited: Sep 20, 2006
  18. ice_cool

    ice_cool Member

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    I really like the checker plate. :)
     
  19. OP
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    crazylittleman

    crazylittleman Member

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    Frame Base/Panel

    Now I have to panels cut and ready to go i could continue with the frame. The panel and L rails for the base were clamped onto and chip board and the joiner pieces are pre drilled on a drill press are put into position. The pre-drilled joiners are used as a template to drill through the L rail and base panel with a cordless hand drill.
    [​IMG][​IMG]

    Rivets are test fitted into the holes.
    [​IMG]

    The L rails are then glued directly to the base panel and riveted in each corner.
    [​IMG][​IMG]
     
  20. OP
    OP
    crazylittleman

    crazylittleman Member

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    Hard Drive Supports

    I finally finished the hard drive supports. I was having issues getting all of the supports to line up so i ended up clamping each set of supports ontop of each other then drilling right through.
    [​IMG]

    The Frame
    I finally completed the top and base of the frame then cut the uprights then today finally dry fitted the entire stack together with clamps.
    [​IMG][​IMG]
    And it all fits. YAY:)

    Thats about all for now.
     

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