Project: 14 TB fileserver? Building a Dual PC tower

[grevaeg]

Hi guys! been lurking around these forums for awhile, but never took the time to register, anyways, just signed up, and ready to post my casebuild on this site =)

Might as well start off with some concept images ( 3dsmax 2OO8 )

http://www.spinnin-wheel.com/images/stories/kart/christersin/rend/casethingy.jpg

http://www.spinnin-wheel.com/images/stories/kart/christersin/rend/disksok.jpg

http://www.spinnin-wheel.com/images/stories/kart/christersin/rend/fron2.jpg

http://www.spinnin-wheel.com/images/stories/kart/christersin/rend/front.jpg

-------The idea-------

The main idea behind this project was to create a silent running file server with lots of physical space to fit all the HDD's i would need to store, uhm... stuff, and equip it with a large ass radiator to remove all the heat created, i wanted the tower to have room for 2 motherboards, just for the simplicity of having one gaming computer and one running as server in the same case, as the main aspect of this build would be silent operation , i went for 3x 250mm mist fans, and another 8x 120mm noctuas to cool things off...

-------The hardware------

--Hardware-- PC1
Asus P5K - Deluxe, p35
4gb pc 9200 ocz flex
Radeon HD3870x2
Q6600 - G0
X-fi, extreme gamer

--Hardware-- PC2
Asus P5N32-E SLI
OCZ NvidiaSLI XTC 4GB PC8500
Asus 8800GT
Q6600 - G0
X-fi, extreme gamer

--Disks--
4x 74gb toshiba 15k rpm SAS
16x 500gb Western Digital - 16mb 7200rpm - SATA
8x 750gb Western Digital - 16mb 7200rpm - SATA
4x 500gb Western Digital - 16mb 7200rpm - IDE

--Watercooling--
KTM 525 EXC Radiator
1x Aqua-Medic Oceanrunner 1200l/h pumper
5 meter watehose, 12mm
4 meter foodhose, 42mm
random plummer parts in copper
Random waterblocks

------materials--------
I wanted this case to look decent, and to be honest, aluminium cases got a bit too common for me, so i decided to go with a full plexi casing with a aluminium frame to support it, the harddrive mount ended up in perforated steel plates, somewhat to keep them a bit colder, and somewhat for the looks of it

[grevaeg]

--12.02.2008--

This will just be a repost of my original worklog, to share experiences and maybe give some ideas to people that wanna build up a case too ^^

Afraid i managed to delete the pictures from the original weld prosess, but i will explain whats been done

----materials-----

Started out with finding some suitable aluminium bars at the local iron dealer, after looking around a bit i ended up with 20x20x200mm square pieces, this should be the ideal considering the final weight of the computer, and that it needs some sturdiness to be able to hold it all together

Bought up about 10 meters, and started cutting/clamping and welding the pieces together

All the welds has been done on both sides to ensure its strong enough

------The result-----

http://rmk-norge.no/images/stories/case/img_2401.jpg
The front

http://rmk-norge.no/images/stories/case/img_2406.jpg
The bottom, probably where the disk mount is gonna be placed

http://rmk-norge.no/images/stories/case/img_2402.jpg


http://rmk-norge.no/images/stories/case/img_2403.jpg
Radiator area

http://rmk-norge.no/images/stories/case/img_2405.jpg


--16.02.2008--


Motherboard tray attached to the frame, drilled up, and popped in place

http://rmk-norge.no/images/stories/case/img_2563.jpg
Backside of the case

http://rmk-norge.no/images/stories/case/img_2564.jpg
6mm pop's holding stuff together

http://rmk-norge.no/images/stories/case/img_2565.jpg
...............

http://rmk-norge.no/images/stories/case/img_2566.jpg
Lian Li Mobo plate mounted =)

http://rmk-norge.no/images/stories/case/img_2567.jpg
20x20x3mm angled up to create a mounting point for the mobo plates

http://rmk-norge.no/images/stories/case/img_2568.jpg
Just drilled a few holes and popped it to the rest of the frame

http://rmk-norge.no/images/stories/case/img_2582.jpg
Cut up another 4 pieces in 20x20x3mm alu, thats gonna create the mounts for my harddrives

http://rmk-norge.no/images/stories/case/bolt.gif
The main idea behind the entire harddrive mount is that the coloumn of disks shouldnt be in contact with the main frame of the case, as this will result in vibrations going too the floor, and causing unpleasant noise, there will be a few 15k rpm disks in here, so managing to keep the vibration away is crucial. The way this one work is quite simple, it will be a rubber tube holding the bolt up, so it wont be in contact with the other frame, trying to illustrate =)

http://rmk-norge.no/images/stories/case/img_2589.jpg
Cut up , polished, and ready for mounting

http://rmk-norge.no/images/stories/case/img_2592.jpg
Rubber thingy good to go

http://rmk-norge.no/images/stories/case/img_2590.jpg
8mm rubber connection ensure no vibrations will be transfered further on in the case

http://rmk-norge.no/images/stories/case/img_2595.jpg
Steel pop's, can take a tremendous amount of weight before getting loose, alot more sturdy then their alu brother

http://rmk-norge.no/images/stories/case/img_2594.jpg
Ended up with perforated steel to create the disk mount, this should ensure somewhat better airflow, it wont get bendt that easy, and it transfers heat better then alu ever will =)

[grevaeg]

--16.02.2008--

http://rmk-norge.no/images/stories/case/img_2561.jpg
My plexi package arrived =)

http://rmk-norge.no/images/stories/case/img_2570.jpg
over 5 square meters of red, clear and dark coloured plexi ^^

http://rmk-norge.no/images/stories/case/img_2572.jpg
The plexi i had ordered were mostly precut to meet my requirements for it. Placed it all up, taped it, and good to start working

http://rmk-norge.no/images/stories/case/img_2573.jpg
The top taped up too

http://rmk-norge.no/images/stories/case/img_2575.jpg
Ready to mount the first 250mm fan, welcome to your new home ^^

http://rmk-norge.no/images/stories/case/img_2576.jpg
Tape ftw!

http://rmk-norge.no/images/stories/case/img_2579.jpg
No idea whats this one is called in english, but lets just go with large ass dremel for now, taped the edges to prevent the cutting blade to slip , and scratch up the oh so fragile plate

http://rmk-norge.no/images/stories/case/img_2580.jpg
Got it all smoothened up

http://rmk-norge.no/images/stories/case/img_2581.jpg
And another one coming up

http://rmk-norge.no/images/stories/case/front/img_2611.jpg
First one mounted up =)

http://www.spinnin-wheel.com/images/stories/kart/christersin/done/img_3003.jpg
There we go =)

[grevaeg]

--------- Building a custom water reservoir--------

I also wanted to get some place to store my coolant, so came up with a decent idea on where to store it all

After a visit to the local plumber, i ended up with the following:

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2701.jpg
2 meter 45mm rubber hose, cut up in 1 meter lengths, and yea... they are ALOT larger then the picture gives a impression of

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2702.jpg
Misc stuff bought inn for the occasion

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2703.jpg
All welded up and good to go

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2706.jpg
Tightened up with some hose clamps to keep the water from leaking out

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2709.jpg
And this is how copper looks after being polished up

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2708.jpg
And there we go, one custom reservoir

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2710.jpg
Cut out a plate of lexan i had around in the shop, and mounted it to this one

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2776.jpg
Plate mounted up using self drilling bolts

Should look pretty awesome when you get some colored water trough it =)

--03.03.2008--

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2766.jpg
Bought in about 12 meter of normal rubber bands to seal of vibrations between the plexi and the frame

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2768.jpg
And the appropriate rubber sealing for the end of the alu squares

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2769.jpg

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2770.jpg


http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2773.jpg
Again, lost some images in the progress, and YES i know the plexi is dirty.

Anyways, since im working around in a bikeshop i found a few of those iron pieces that will save ur plastic when u happen to tip over on ur bike, made some holes, and threw some bolts trough em, same goes with the plexi

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2774.jpg
The bottom

http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2775.jpg
Sideview :p



http://www.spinnin-wheel.com/images/stories/kart/christersin/img_2778.jpg
No pictures for this process either im afraid, but quite simply used one of those wood drills with 120mm size to get the holes done

http://www.spinnin-wheel.com/images/stories/kart/christersin/kopi%20av%20img_2779.jpg
The backside

http://www.spinnin-wheel.com/images/stories/kart/christersin/kopi%20av%20img_2771.jpg
And heres the bolts! directly from bauhaus =)

http://www.spinnin-wheel.com/images/stories/kart/christersin/kopi%20av%20img_2782.jpg
....

[grevaeg]

-------The watercooling--------

http://www.nengun.com/image/catalogue/original/nengun-0701-00-koyo-radiator.jpg
The radiator looks something like this =)

As i stated earlier, some of the point of building this computer, was to make sure its silent, and can run efficient on low voltage fans

ended up with using a KTM 525 EXC radiator, this alone should be able to dispatch alot more heat then the normal "pc radiators" u can get around there

Also made a custom fan duct out of plexi to make sure all the air goes trough the radiator, and not everywhere around it

http://www.spinnin-wheel.com/images/stories/kart/christersin/done/img_2998.jpg
Created the fanduct in 3mm plexi, easily cut up with my "dremel" :P

http://www.spinnin-wheel.com/images/stories/kart/christersin/done/img_2999.jpg
Another angle

http://www.spinnin-wheel.com/images/stories/kart/christersin/done/img_3000.jpg
used m8 bolts to make sure the radiator fit well into the rest of the case

http://www.spinnin-wheel.com/images/stories/kart/christersin/done/img_3001.jpg
Used some tube aluminium to cover up the bolt, and to make sure its stable to the rest of the case

http://www.spinnin-wheel.com/images/stories/kart/christersin/done/img_3002.jpg
10mm outlet from the hose, should ensure enough flow =)

Enough for now, ill post some more tomorrow =) And thanks alot luke, ill get confy ^^.

[grevaeg]

i cant wait to see how you are going to manage all those cables...its going to be a nightmare
Cabler ARE gonna be a mess, gets the chills just thinking a bout all those sata and power cables stretching around in there -.-


Incredible work, man... and what a project!
+rep for the sheer SIZE of it.
Thanks dude =)


i think youre going to need more jiggawatts......

looks great...i have a mod that similar in design comin up
Have 2x thermaltake 1200w thoughpowers around, shouldnt be much of a problem with wattage :P

And no FrooP, im from norway, sorry :P

[grevaeg]

Wow... didnt expect a frontpage view all of a sudden :P

Ill get some more pics up today, thanks for comments people ^^.

[grevaeg]

Ya, It's called galvanic corrosion. I don't think it occurs very fast but over time can cause problems like leaking and such.


This is easily prevented with a coat of clear paint =)

[grevaeg]

Ah well, here we go again =)

Posting up some pics on the case before stashing all the hardware inn there, enjoy ^^.

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3003s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3003.jpg)

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3004s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3004.jpg)

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3007s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3007.jpg)
1cm room between the two top plates, and 1cm room between the two front plates to ensure good airflow and a decent looking fan grill :P

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3008s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3008.jpg)

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3009s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3009.jpg)

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3010s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3010.jpg)

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3011s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3011.jpg)

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3012s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3012.jpg)

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3013s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3013.jpg)
Fans in place and good to go

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3014s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3014.jpg)

http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3015s.jpg (http://www.spinnin-wheel.com/images/stories/kart/christersin/tbcs/img_3015.jpg)

[grevaeg]

thx for rep guys , really appreciated ^^.

Ill get some more updates out later today most likely

[grevaeg]

Well... the "mesh" you are referring to is actually 3mm perforated steel, not alu, so its more then sturdy enough to hold the disks without moving, its troublesome enough to bend by hand, so doubt a straight downforce would do anything to this one =)

Ill get some more updates up later today most likely ^^