Worklog: Massively (Update #65, 29th Nov – Final Pics + Aussie copper pipe fittings!)

Discussion in 'Modding Worklogs' started by Saate, Mar 29, 2012.

  1. the3coopers

    the3coopers Member

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    I think that one's been linked here before. I've certainly read it.

    One thing I really like is the way that he made the acrylic covers instead of using the rubber grommets in the backplate. It just keeps the braided cables nice and neat, rather than the usual "messy spaghetti" look that some modders seem to love.

    EG: http://img194.imageshack.us/img194/5965/dsc0269p.jpg
     
  2. BigDave

    BigDave Member

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    Wasn't sure if it had bee seen and posted it all the same. I do see what you mean though :thumbup:
     
  3. Dumpty

    Dumpty Member

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    I saw this on some viewers choice comp this was in. I really love what he did with res and the mid plate gave it a sci fi movie feel. And like Coops said the way he did the cable management
     
  4. BlueRaven

    BlueRaven Member

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    Haven't dropped in for a while, looking great mate!
    All the effort you are putting in will surely show in the finished build.

    WD40 will work alright for cutting ally but proper Cutting Oil will make your holesaws last longer, especially if you need to cut steel too.

    Like Coops said, Sutton are the best but the proper Sutton arbors aren't cheap (and the quick-change ones are even more expensive). Although they will last for years if looked after.
    And you can just buy new saws when you need a particular size or when they wear out.
     
    Last edited: Feb 13, 2013
  5. Bastard Child

    Bastard Child RIP

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    Oh my god Saate - I have hairs on my nuts younger than this build :Paranoid:
     
  6. pieceofchance

    pieceofchance Member

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    Is that your new affectionate pet name for the OKC skanks?
     
  7. Bastard Child

    Bastard Child RIP

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    If they were skanks it wouldn't be so much work getting them to put ou *cough* never mind ಠ_ಠ
     
  8. trippinonprozac

    trippinonprozac Member

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    Just wanted to drop past your build log and show some support. Was awesome to see all this coming together in person on the weekend. The amount of effort and time that has gone in to this build is nothing short of amazing and I look forward to seeing the final product.

    Keep up the great work!
     
  9. OP
    OP
    Saate

    Saate Member

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    Yeah I definitely like all the custom covers and stuff, next build for sure! :p

    Thanks Dave :)

    Thanks mate, always appreciate the tips and feedback :)

    The man himself! :) I know I said it once before, much earlier in this thread, but thanks for the awesome Solid Edge guide - it’s helped me hugely with the build!
    Thanks mate :) Always nice to be able to talk through stuff I’m working on with other modders, we’ll have to organise a BBQ or something with more OCAU locals when the build is finished – which incidentally I hear will be around March 2017 :p

    UPDATE – Custom HDD Bay

    I have to apologise for the delay in updates folks. It’s really not that I havent been working away on this – more that the metalwork is just taking me longer than I expected! I keep spending hours-long sessions working away on it and even though I’m documenting and photographing what I’m doing it doesn’t feel like there’s that much interesting progress being made.

    I’ve got about 100 photos of the work done over the past couple of weeks which should be more than enough for a few updates. I want to rely on you guys, though, to tell me if you’d prefer updates to cover more progress than the typical ones I post with all the gory details. I’m sure you’ll still enjoy reading them, but at the same time I’m concious that I really want to power through and finish this build! Anyway – enough words, I’ll get on with the update but do please let me know what you’d prefer in regard to the level of detail!

    I’ve attached the two 5mm aluminium pieces of the HDD Bay together so that I can scroll saw and file together and ensure they’ll align perfectly later on when the bay is constructed.

    [​IMG]

    I accidentally discovered a pretty useful technique in the process of filing the edges of the pieces together. Since I was planning to have the 5mm pieces clamped together while I was filing I put some double-sided tape inbetween the pieces to add a bit of tack and stop them slipping out of alignment.

    After filing one of the long edges and removing the clamps I thought it was pretty remarkable how good a job the double-sided tape was doing at keeping them together! At the time I just put it down to the clamping process making the tape ‘work real good’ but some time later discovered what in hindsight is obvious – the friction from the filing heated the pieces enough that the tape inbetween had melted and become more like a glue! Very handy and easy enough to remove later!

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    The first slot cut - in what would prove to be a very time intensive piece of work! Cutting through 10mm Aluminium with a scroll saw requires patience – absolutely no issues with the scroll saw doing the job, just takes a while. Waynio’s [ mod over at bit-tech was a great help and inspiration for me in getting through this – the work he’s done with his Scroll Saw and Aluminium is amazing!

    [​IMG]

    [​IMG]


    Second slot down, at this stage I had no idea how much filing I would have ahead of me :p I’ll invest in a jigsaw before I do something like this again, but it’s been a valuable learning experience and practice so definitely has been worthwhile.

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    I timed it on this bit, it took 8 minutes 16 seconds to do the cut you see:

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    Three down, two to go:

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    Done! Now to clean it up:

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    Filing process underway, still lots to go but you can see a lot of the excess crap is starting to disappear:

    [​IMG]

    3.5” Slots tidied up a bit but the SSD’s still have to be worked on:

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    My garage floor, over the coming days and weeks I’d get used to being covered in this:

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    Beginning to work on the SSD slots, before and after some tidy up:

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    Marking the areas that need to be levelled off then more filing:

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    When I drew up the original plans for this HDD Bay I used SSD dimensions I’d looked up online. After comparing the size of the Corsair Force GT SSD I have to the slot I realised it wasn’t going to be big enough. Looking at the couple of SSD I had floating around I discovered that they’re all very slightly different sizes – the holes for screws line up on all of them, but the cases are all different. This can only mean one thing – more filing is needed!

    Masking tape and measuring to take the extra 1-2mm off the length:

    [​IMG]

    Same again on the width of the 3.5” Bay Slots:

    [​IMG]

    Then more filing:

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    Phew!

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    This update feels like it’s gone on forever so I’ll leave it there for today, I have enough work saved up to do more updates fairly soon so I’ll see how I go for time! Even though I’m extremely aware that I’ve done this in an overly laborious way I feel like I’ve learned a lot from the time invested, and it’s turning out how I want, so apart from the slowness I’m pretty happy with how its going. Would be great to hear what you guys think!
     
  10. the3coopers

    the3coopers Member

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    I just hope that you didn't use the one hand when you did all that filing, otherwise nobody is going to believe that you have a girlfriend.

    [​IMG]

    .
     
  11. Kommandant33

    Kommandant33 Member

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    LOL coops..

    C'mon Saate - quit your day job, we need MOARfrequentupdates bro..
     
  12. Bastard Child

    Bastard Child RIP

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    You're welcome Mr S, you take mean pics :thumbup:
     
  13. pieceofchance

    pieceofchance Member

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    Not an Arrested Development reference is this?

    You don't have to wear an "MRS" bracelet or anything do you Saate? :lol:

    EDIT: Oh, and keep up the swarf pron mate :thumbup:
     
    Last edited: Feb 27, 2013
  14. D_MaN

    D_MaN Member

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    Fantastic build mate!
    I love reading your progress updates, keep em coming.
     
  15. Dumpty

    Dumpty Member

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    oh nearly there Saate! sprint to the finish? i rather you do a proper job tho. :p
     
  16. WishBone17

    WishBone17 Member

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    hey saate, how do you ensure those slots stay nice and straight when filing it down, it looks pretty damn straight to me, I would think you would somewhat over-file and the sizes may differ by mm.
     
  17. DeadLetter

    DeadLetter Member

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    This entire work log is just too much fun to look at. So much porn for the eyes :D
     
  18. Kommandant33

    Kommandant33 Member

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    I would say by using the vice as a guide as per this pic

    http://farm9.staticflickr.com/8512/8485162728_c895c0baa6_b.jpg
     
  19. WishBone17

    WishBone17 Member

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    "ohhh i see" - said the blind man
     
  20. OP
    OP
    Saate

    Saate Member

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    Thanks mate :)

    Thanks Dumpty, makes me relax a little – but the end is in sight now so on we march!

    Glad it looks straight! I’ll take that as a compliment that I’m learning :p To be honest I tried a lot of things initially, like clamping a cheap metal ruler along the line to stop me going ‘over’ and stuff like that. Honestly what’s worked the best is to use masking tape and rule a line, then I file directly to that line and its fairly straight. After that I use a square or just something flat to check for high points that my eye isnt seeing and mark them all with permanent marker – then just clean them up and recheck a few times until I’m happy.

    The other thing I keep in mind is that these arent engine parts so the tolerance for measurements and filing to be out is fairly high, fractions of a mm is probably fine in the long run!

    Thanks DeadLetter :)


    UPDATE – Custom HDD Bay Continued

    The custom midplate saga continues! After tidying up the slots for the 3.5” drives I grabbed an old 500GB drive to test the fit and was less than impressed to discover I still needed to take 1-2mm off the width of the slots for the fit. I assumed this was because I’d made a mistake and based the slot-size in my plan off the precise dimensions of the hard drives – and in doing so not allowed for any clearance to fit the drive in. I double-checked the measurements and marked the areas that needed to be filed further:

    [​IMG]

    [​IMG]

    In what I can only put down to amazing luck, before I started filing I decided to grab one of the WD 2GB drives that would be going into the build and test it out instead of the 500GB drive. Amazingly it fit – perfectly! Since drive bays in stock cases are basically a one-size-fits-all deal for 3.5” bays I was pretty surprised to discover the newer drives are a few mm slimmer. As long as the mounting holes are in the same spot and they’re not making the drives larger I guess they can safely play with the dimensions like that.

    It’s little changes like this that are precisely the reason I wanted to build up a collection of old/broken drives for sizing. I’ve got a Corsair and OCZ SSD that are both slightly different sizes, and different again to the couple that CrocodaVe gave me – madness I tell you! :)

    [​IMG]

    [​IMG]

    It’s a fit! At this stage you have no idea how relieved I am that I avoided oversizing the slots, I probably could have padded them or something to recover the design but it would have rocked my confidence after all the time I’ve put into this piece.

    [​IMG]

    I like to get the harder stuff done first, so now that the 3.5” Slots are finished it’s time to clean up the two SSD slots. They’re a little undersized at the moment and the lines in this shot show the filing work I’ve got ahead of me:

    [​IMG]

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    Getting there! The lines on the sticker underneath messed with my head a little on the SSD slots. I kept thinking the slots weren’t square and didn’t look right because of the irregular angle clashing with the sticker lines.

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    The SSD fits! Woohoo!

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    So after all this work it would be an understatement to say I was a little paranoid about drilling and tapping into the 5mm width of the pieces! I decided to do a few practice taps on scrap before risking my work, and after a few attempts I wasn’t getting consistent results from my cheap tap set – the wrench that came with the set kept undoing itself and releasing the tap halfway through. I decided it would be well worth it to invest in a nicer set so picked up this one:

    [​IMG]

    [​IMG]

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    The quality is superb and it works perfectly – a huge relief :) After being satisfied that tapping wouldn’t be a problem my next challenge was to figure out how to drill into the end of longer workpieces that don’t fit under the drill press. I could clamp it to the bench but if drilling by hand I wanted to use a guide to make sure I’d get the hole in the right spot, here’s me testing the solution I came up with:

    [​IMG]

    Testing it out on the larger piece, clamped down with the guide in place:

    [​IMG]

    ..and tapped!

    [​IMG]

    I had a look at how the piece would look with the stands I’d designed and wasn’t really happy with the look. At the moment the stand is slightly interesting to me because the sticker provides it with some character – but realised once the sticker’s gone it’s just going to be a solid chunk of alu sitting there:

    [​IMG]

    So went back to the drawing board and come up with a replacement stand that I think will work much better. I’ll end this update with a small preview! The small slots near the top are to hold the underplate of the HDD bay, that’ll become clearer in the next update. What do you think?

    [​IMG]
     
    Last edited: Mar 12, 2013

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