1. OCAU Merchandise is available! Check out our 20th Anniversary Mugs, Classic Logo Shirts and much more! Discussion in this thread.
    Dismiss Notice

Project: Big Loud Server

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

  1. renegadefighter

    renegadefighter Member

    Joined:
    Oct 22, 2002
    Messages:
    712
    Location:
    BNE.QLD
    why do you need so much storage? the wow-factor is cool, but I cant grasp why..
    care to enlighten me?

    great work on the case crazy. looks good. the checkerplate looks good for it. :D
     
    Last edited: Dec 21, 2006
  2. ener

    ener Member

    Joined:
    Dec 23, 2005
    Messages:
    3,620
    Location:
    Gold Coast
    sparetime + no gf = salvation
     
  3. rainwulf

    rainwulf Member

    Joined:
    Jan 20, 2002
    Messages:
    4,276
    Location:
    bris.qld.aus
    Well if i didnt need the storage, i wouldnt need the storage :)
    My original aim is to do a direct copy in both capacity and data content of the bigger server and then take the old bigger server offline and use it for backup.

    Now i have run out of cash, so atm its only got about 1.5tb sitting in it, and i use it for a data dump.
    I have to save money to get my bike and car fixed.
     
  4. OP
    OP
    crazylittleman

    crazylittleman Member

    Joined:
    Sep 21, 2004
    Messages:
    895
    Location:
    melbourne
    I normally get which ever brand of drive msy has in stock at the time. Judging by the drives i currently use the Western Digital appears to run the coolest although i suspect this is more due to a dodgy temp sensor rather then actual performance.

    Wiring

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    the wiring for the front four 120mm fans connects via a 12 pin connector. Wiring for this runs along the base of the case to the fan controller at the back.

    [​IMG]
    Due to the lack of a windows appearance was unimportant so adhesive mounts and cable ties will do to secure everything.
    [​IMG]
    Once the panels slide on they are secured but a piece of L rail edging screwed on in two places.
     
    Last edited: Dec 30, 2006
  5. Techocity

    Techocity Member

    Joined:
    Nov 18, 2006
    Messages:
    20
    omfg its big, its gota be loud :tongue: .... and defenatly is a server :o ..... enjoying it mate keep it up... :thumbup:
     
  6. Odje

    Odje Member

    Joined:
    Jun 27, 2001
    Messages:
    2,303
    Location:
    Sydney
    I am looking to making something similar. Where did you get the Al L brackets and Al checker plate from? How much was it? What tools did you use to make those joins? The joins look very time consuming but worth the effort. How much time did the whole thing take? Where and how much was the 120mm hole saw?
     
  7. OP
    OP
    crazylittleman

    crazylittleman Member

    Joined:
    Sep 21, 2004
    Messages:
    895
    Location:
    melbourne

    All of the L brackets are from bunnings, they come in 3m lengths which are ~$20 each.

    The Checkerplate I got precut to size from a place called Action Aluminium in Dandenong Vic, all up that was $95.

    The corner joins were time consuming to begin with but after the first 2 or 3 i became proficient at them, with the rivets and Araldite they have proved effective.

    I started the case in september and worked on it almost every day for a week and a half, i then spend i few hours a weekend working on it since then.

    Tools I used
    -Mounted Mite Hacksaw
    -Cordless Battery Drill
    -120mm Holesaw ($110 from bunnings with an arbor)
    -Drill press
    -Metal Punches
    -Collection of metal files
    -20bit drill set
    -Rivet Gun
    -Collection of G clamps
    -Dremel + reinforced cut off discs.
    -92mm holesaw (part of a $9 set i found at bunnings)
    -Bench Mounted Vice
    -Metal rulers, set square, etc,

    If you are planning to use a load of the L rail alu instead of getting it from bunnings just work out how much you need and get it all in one lot from a specialist metal place. This will work out a load cheaper.
     
  8. MrSmith

    MrSmith Member

    Joined:
    Jul 7, 2005
    Messages:
    2,376
    Location:
    nor perth
    How do those handles go? WIth a full load.. THere'll be a fair bit of stress happening around those handles with such a heavy load :lol:
     
  9. Odje

    Odje Member

    Joined:
    Jun 27, 2001
    Messages:
    2,303
    Location:
    Sydney
    How easy is it to countersink the pop rivets?
     
  10. OP
    OP
    crazylittleman

    crazylittleman Member

    Joined:
    Sep 21, 2004
    Messages:
    895
    Location:
    melbourne
    It's not that hard, I used a 1/4" drill bit and a turn the handle hand drill (gives best control over speed and pressure). Once the rivet is pulled up the counter sinking only has to be 2-3mm deep to completely conceal the rivet head.

    They haven't broken yet. I ended up putting just one handle on the back, having one hand on the back handle and one under the front of the case is the best for lifting it up onto tables and what not. The top panel loads most of the case's weight across the entire top of the case not just the back cross piece.
     
  11. Kennyken

    Kennyken Member

    Joined:
    Jul 18, 2005
    Messages:
    75
    Location:
    Adelaide
    Mate, that is looking awesome. If your worried about some noise, get that sound proof foam. Can pick up massive sheets in adelaide for under 40bux and makes em quiet. Thinking about getting some myself but im lazy.
    Keep it up:)
     
  12. OP
    OP
    crazylittleman

    crazylittleman Member

    Joined:
    Sep 21, 2004
    Messages:
    895
    Location:
    melbourne
    I'm not that concerned with the noise. Theres a few little design flaws in the hard drive stack that are limiting airflow and creating extra noise but they can be sorted in future.
     
  13. Meddish

    Meddish Member

    Joined:
    Dec 5, 2006
    Messages:
    803
    Location:
    Newcastle
    Just wanted to ask the 120m Super expensive holesaw does it do a better job then the 92mm cheapy
    oh and the 120mm holesaw actualy 120mm?? cuz the largest my local bunnings had was 111mm! (and they where USELESS!!! I had to ask 4 guys to find out if they had larger)

    and whats the rough cost so far??
     
    Last edited: Jan 15, 2007
  14. OP
    OP
    crazylittleman

    crazylittleman Member

    Joined:
    Sep 21, 2004
    Messages:
    895
    Location:
    melbourne
    It was a 119mm holesaw. The difference between the holesaws is the expensive one did 5 holes easily while the cheap one did one hole and judging by the condition it was in afterwards I don't think it would have survived another.
     
  15. Meddish

    Meddish Member

    Joined:
    Dec 5, 2006
    Messages:
    803
    Location:
    Newcastle
    ok well then ill keep to the jigsaw for the moment... then maby next project i can justify the $100 outlay for the holesaw
     
  16. Meddish

    Meddish Member

    Joined:
    Dec 5, 2006
    Messages:
    803
    Location:
    Newcastle
    so when do we see some final pictures???

    and i want to see some temps... if this works i might wanna pinch some ideas for my own server....
     
  17. OP
    OP
    crazylittleman

    crazylittleman Member

    Joined:
    Sep 21, 2004
    Messages:
    895
    Location:
    melbourne
    [​IMG]

    Thats how its running at the moment. I still have to get some rubber washers and mount the hard drives properly before i take some interior shots.
    At a 25C ambiant the drives stay at a steady 32C under load. Although thats just based on the SMART sensors in the drives, I dont really put a whole load of faith in them.
    One major design flaw.
    [​IMG]
    You can see there is a gap of about 8mm between the side of the drive and the L bracket that is supporting it. This leads to air flow across the top of the drives but dead spots of little air flow along the sides. In hinsight i should have cut the L support rails like this.
    [​IMG]
    Another problem is the checkerplate looks sweet and if very tough but its very hard to work with. If i had my time again i would have made the back panel from just plain aluminum plate, this would have made cutting the various holes easier and achieved a cleaner result.
     
  18. Meddish

    Meddish Member

    Joined:
    Dec 5, 2006
    Messages:
    803
    Location:
    Newcastle
    does the HDD 'cage' get hot???
    and does it transfer heat??

    also how loud is LOUD?!?!?!?!?!

    oh a suggestion as they are all HIGH flow fans... get some tissue paper (2 sheets) and put that between 2x fans grills and put that on the frounts to keep dust out!
     
  19. pooger

    pooger Member

    Joined:
    Mar 17, 2003
    Messages:
    511
    Location:
    Pants
    FUCK ME WE NEED MORE CAPS AND !!!???!!!?????!!!!!!!????

    On-topic: very nice case.
     
  20. OP
    OP
    crazylittleman

    crazylittleman Member

    Joined:
    Sep 21, 2004
    Messages:
    895
    Location:
    melbourne
    To be honest the heat transfer from drive to the cage is pretty poor, at the time I did the design i didn't really know what i was doing, i thought the best way was to try to get the most airflow around the drives with out much thought into using the cage as a heatsink. Turns out that was a bad plan.
    I have the fans running at 7V so the noise isnt that bad. Its more of a dull roar.
    Yeah I;ve noticed a bit of dust build up on the drive so ive been planning to get some screw on dust filters for the back of the fans when i get the chance.
     

Share This Page

Advertisement: