Trek

[DarthBeavis]

Copying my worklog from elsewhere then will have updates:
This project will be themed on the utility case a Star Trek Engineering away team might take on a mission. Technology featured in this build will include Nvidia's 3d Stereo graphics for the most immerse gaming short of a holodeck. The build will contain two mini-itx based systems for true head-to-head gaming. The project is a join venture between BoxGods (a.k.a. Geno) and Out of the Box Mods (a.k.a. me). Our goal is to have it premier at QuakeCon (Nvidia has booth space reserved for it) then next travel to PAX.

Sponsors:
- Nvidia (3d monitors, glasses)
- Danger Den (CNC, laser, design services, I think I bought all the water-cooling parts retail for this project except GPU blocks)
- Crucial (Ballistix Tracer ram and SSD hard drives)
- Performance PCs (tons of stuff)
- Mountain Mods (thanks for helping get materials on short notice Ben!!!)
- BoxGods (aluminum boxes and tons of design services)
- Asus (motherboards)
- I wanted to fit FrozenQ reservoirs in but the space is so small he would have to make really small ones. I do not know if he will have time. Anyway, he still deserves a shout out.

Geno, after months of work and more than one sleepless night and shower less day has the drawings finished. I received the aluminum boxes Friday, then traveled to Danger Den Saturday. Jeremy, the CEO of DD, was kind enough to give up his entire day to draw the holes for the case where I needed them and then use one of their CNC mills to cut the holes. This week they will laser cut the acrylic parts as well. Today I ground the slag off the boxes and radiused the edges (Geno already has some of it done so I would know what result to shoot for). This is my FIRST time working with metal so please keep that in mind when commenting. I still have to do use the Scotch Bright finishing sander attachment (this round was with a number 80 flap attachment). Tomorrow I will start the polishing . . .w00t

Drawing (not complete):

http://img364.imageshack.us/img364/705/displayback5845563.jpg

CNC Mill:
http://img204.imageshack.us/img204/3484/ddmill5837694.jpg
http://img508.imageshack.us/img508/8804/dsc017005721614.jpg
http://img521.imageshack.us/img521/2190/dsc017015725911.jpg
After mill:
http://img36.imageshack.us/img36/5195/dsc017065730633.jpg
http://img193.imageshack.us/img193/5574/dsc017175787762.jpg
Grinding (Geno I do listen to your safety nagging):

http://img40.imageshack.us/img40/1193/dsc017115764189.jpg
http://img521.imageshack.us/img521/6724/dsc017135768651.jpg
http://img364.imageshack.us/img364/7312/dsc017145773087.jpg
http://img508.imageshack.us/img508/5640/dsc017155780598.jpg

Guess I have a date with a file and sandpaper tomorrow as well . . . .maybe polishing on Tuesday?

[DarthBeavis]

Here is a different perspective with more details drawn in:
http://img229.imageshack.us/img229/1443/76803476.jpg

[DarthBeavis]

Did what I could metal-working on teh boxes, but got some pros to help get it rightly polished up. here is the center box. The other two are already at the painter who will paint the inside metallic teal then clearcoat the inside and outside of the boxes. I might also have them paint the PSU ;)

http://img38.imageshack.us/img38/1208/dsc017180391741.jpg
http://img20.imageshack.us/img20/2695/dsc017190395955.jpg
http://img40.imageshack.us/img40/4683/dsc017200400375.jpg

Brian from Primochill came though in a pinch with laser cutting.

http://img181.imageshack.us/img181/4048/img0360b.jpg
http://img258.imageshack.us/img258/5492/img0361k.jpg

[DarthBeavis]

Moar Shiney . . .also filed the corners of the reservoir hole so it will sit flush. It will have one of the new billeted aluminum face plates polished to match the case

http://img444.imageshack.us/img444/8441/dsc017387951433.jpg
http://img207.imageshack.us/img207/1913/dsc017367943237.jpg
http://img33.imageshack.us/img33/1156/dsc017347938719.jpg
Thanks to Asus and Crucial for sponsoring hardware:
http://img207.imageshack.us/img207/3888/dsc017327929178.jpg
http://img444.imageshack.us/img444/7540/dsc017337933452.jpg
http://img338.imageshack.us/img338/4967/dsc017317905768.jpg

Mobos and GPUs went back to asus as t hey did not fit

[DarthBeavis]

Decided to get some painting done. The pump and rads really will not be visible but I wanted to at least have them reflect some light to maybe help light up the 'nacelles' or laminated acrylic layers between the boxes
http://img33.imageshack.us/img33/1314/dsc017396988561.jpg
http://img55.imageshack.us/img55/2146/dsc017406993006.jpg
http://img195.imageshack.us/img195/2889/dsc017417057481.jpg
http://img366.imageshack.us/img366/7397/dsc017427061756.jpg
Geno says I will have some sanding and polishing of the edges of the acrylic pieces when they get here so I stocked up on compounds (also need to polish the knobs . . .errr, that did not sound right . . .uh handles for adjusting the monitors)
http://img65.imageshack.us/img65/9789/dsc017437124020.jpg

[DarthBeavis]

Got the PSU put together after painting (finally a silver Silverstone) . . .then started violating my diet by consuming a steady stream of gin and tonics . . .
http://img43.imageshack.us/img43/1954/dsc017537616662.jpg
paint used:
http://img524.imageshack.us/img524/1706/dsc017548953627.jpg
Got the boxes back from painting:
http://img14.imageshack.us/img14/7233/dsc017586040444.jpg
http://img8.imageshack.us/img8/9835/dsc017596045211.jpg
http://img14.imageshack.us/img14/5978/dsc017606049767.jpg
Wish I had the pump painted teal as well:

http://img165.imageshack.us/img165/9471/dsc017616054624.jpg

[DarthBeavis]

http://img9.imageshack.us/img9/458/dsc017634439191.jpg
got the acrylic pieces in from Geno . . .first peeling off all the paper. tomorrow starts sanding and polishing.
http://img442.imageshack.us/img442/7648/dsc017644853038.jpg
http://img196.imageshack.us/img196/1064/dsc017654858326.jpg

to give you an idea of how many parts:
http://img197.imageshack.us/img197/7878/dbpartscut4659355.jpg

[DarthBeavis]

sanding away (batch sand then go back and wet sand with finer grit individually):
http://img527.imageshack.us/img527/7602/dsc017669884779.jpg
http://img150.imageshack.us/img150/2702/dsc017739889290.jpg
http://img529.imageshack.us/img529/8255/dsc017709757450.jpg
Sniipe look what I have in the backround
http://img146.imageshack.us/img146/5121/dsc017719762961.jpg

[DarthBeavis]

fully polished black piece next to sanded black piece (only 100 or so more to go)
http://img170.imageshack.us/img170/2229/dsc017788302587.jpg

That is on the buffing wheel using blue compound and a five sewn wheel

[DarthBeavis]

Polished ALL day long and still went to the gym. Special thanks to my buddy John (SoundEvolution) for spending the last two days sanding with his orbital while I wet sanded and polished. After the project is done I will post some videos of parts of the project.

Here is a test assembly of the center box and one of the side boxes. I got the order wrong as the black layer with the radiator mounts goes next to the bigger center box not the outside box. So far, looking good. I will clean the acrylic up well before final assembly.

http://img7.imageshack.us/img7/4582/dsc017825195615.jpg
http://img34.imageshack.us/img34/8434/dsc017835203046.jpg
http://img19.imageshack.us/img19/1218/dsc017845208270.jpg
http://img263.imageshack.us/img263/2039/dsc017855215220.jpg
http://img7.imageshack.us/img7/1153/dsc017865220104.jpg

[DarthBeavis]

Yes I have some nice 6" UV cathodes and a load of UV LED strips to play with. lights will be remote controlled ;)
Test fitting the wheel assembly (will use different mounting hardware of course
http://img12.imageshack.us/img12/3581/dsc017878181967.jpg
http://img98.imageshack.us/img98/4480/dsc017888187272.jpg

[DarthBeavis]

Don't think I will have all four monitors ready for QuakeCon but I will have them ready by PAX. Need to finish plumbing on side, install mobo and GPU in the other, little wire management, cut acrylic handles and replace the ghetto screws in the top part with better ones tomorrow. Then tomorrow night pack it all up to take on the plane. We cannot finish the monitors until we have a screen panel (Danger Den will cut tomorrow and send to the hotel in Dallas, we will finish the monitors at the hotel).

Monitors:
http://img6.imageshack.us/img6/458/dsc017985827598.jpg
http://img41.imageshack.us/img41/7411/dsc018096397029.jpg
Made backplates for GPUS so I could mount them to the mobo tray:
http://img16.imageshack.us/img16/2482/dsc018015843008.jpg
Sleeving my arse off:
http://img43.imageshack.us/img43/134/dsc018005838204.jpg
Coming together (wife is gonna kick my tail over this mess):
http://img269.imageshack.us/img269/8291/dsc018025848210.jpg
http://img134.imageshack.us/img134/6932/dsc018035853097.jpg
http://img6.imageshack.us/img6/3885/dsc018045858025.jpg
Crappy pic but it shows the lighting (can control it with a remote fob):
http://img269.imageshack.us/img269/2612/dsc018055862517.jpg
http://www.youtube.com/watch?v=C-qsghdeKv8

[DarthBeavis]

http://img199.imageshack.us/img199/3972/dsc018179657788.jpg
QuakeCon went well. I will finish this build by doing two things (will be completed by PAX in three weeks):
1. Install 4 fan rad in center handle assembly (close it off with acrylic)
2. Finish custom monitor enclosures and install them
3. Make up brochures explaining it is a Starfleet Core of Engineers Concept so stop :banana::banana::banana::banana::banana:ing about how it does not look Star Trekkish dammit ;) I swear people just are so literal and can only think linearly
http://img38.imageshack.us/img38/6803/img023312629285.jpg
http://img27.imageshack.us/img27/221/trekplaque.jpg

[DarthBeavis]

Working on monitor enclosures. Have to tap into the controllers boards to get power for fans I am adding to the enclosures. These boxes will connect to the 'antlers'.
http://img188.imageshack.us/img188/6730/dsc01820ndk.jpg

http://img140.imageshack.us/img140/9631/dsc01819a.jpg

I took the small rads out of the aluminum boxes replacing them with a single rad in the new center housing (split off the T3 dual outputs back and back using Bitspower Y connectors - don't know if there is a benefit but I thought why not)
http://img402.imageshack.us/img402/9892/dsc01825.jpg


http://img402.imageshack.us/img402/6036/dsc01824x.jpg


http://img136.imageshack.us/img136/7246/dsc01821h.jpg

T3 cover on:
http://img140.imageshack.us/img140/1260/dsc01830ajm.jpg


http://img513.imageshack.us/img513/8645/dsc01829k.jpg


Re-plumbed and ready to fill and leak test. Used Koolance quick disconnects so I can take the top part off for shipping/transport.
http://img181.imageshack.us/img181/1272/dsc01832x.jpg


http://img297.imageshack.us/img297/4699/dsc01833q.jpg


http://img26.imageshack.us/img26/3192/dsc01834wng.jpg


http://img26.imageshack.us/img26/7096/dsc01835t.jpg

I will also sand down that top piece so it sits flush.

[DarthBeavis]

I have been sitting on this project for a long-time just waiting for the right time to finish it. well, now is the time. Cryptic Studios, the maker of Star Trek Online, is going to sponsor me so I can use this to show off their game. I am going to Danger Den this weekend to finish the new monitor enclosures. After that, the project will be ready to debut in full.

[raistnox]

as much as i dispise star trek this thing is actually cool well done

[billygoat333]

I think its really cool except for the aluminum box... for some reason it screams glorified toaster. and I do mean glorified, that thing is shiny! haha no offense your modsmanship is amazing and I bow down to your skills :bowdown:

[DarthBeavis]

I think its really cool except for the aluminum box... for some reason it screams glorified toaster. and I do mean glorified, that thing is shiny! haha no offense your modsmanship is amazing and I bow down to your skills :bowdown:

this is my first venture into working with metal. I love the combination of polished aluminum and acrylic.

[artoodeeto]

looking pretty sweet so far, I like the way you used the acrylic to break up the polished metal casing.

[billygoat333]

this is my first venture into working with metal. I love the combination of polished aluminum and acrylic.

Trust me you did much better than I could have. ;)

[x88x]

Very nice. I love the back to back dual head monitor design. It should look amazing when it's complete. :D

[Kayin]

Is that one of Geno's new T3 reservoirs? I'd love to know if he got the cracking issue fixed...

[DarthBeavis]

Is that one of Geno's new T3 reservoirs? I'd love to know if he got the cracking issue fixed...He has separated from Primochill and it taking his designs elsewhere. That is one of the first ones you see, not sure if it is cracking or not to be honest

[Kayin]

Is he releasing a new version? Glad to know about Geno, as well.

[DarthBeavis]

I hate the monitor enclosures so I am going to design something different. It will continue the green and black design element and will be more like brackets that wrap around the monitor instead of entirely enclosing it. Will look much better. here is the ghetto enclosures installed (was going to install pieces to cover up teh seams by instead time to make it look tight).
http://img822.imageshack.us/img822/4474/dsc02404.jpg
http://img15.imageshack.us/img15/9989/dsc02405rr.jpg
http://img576.imageshack.us/img576/3705/dsc02407a.jpg
http://img708.imageshack.us/img708/6783/dsc02408p.jpg
http://img576.imageshack.us/img576/2153/dsc02409p.jpg
Internal pix:
http://img149.imageshack.us/img149/384/dsc01875mj.jpg
http://img27.imageshack.us/img27/9240/dsc01876t.jpg
http://img147.imageshack.us/img147/2645/dsc01827ho.jpg

Hate the sata cables will redo them

[StormRider]

now that is one ridiculously cramped case

[Okele]

Grats on all the sponsorships, I play STO on occasion, glad they felt the need to sponsor you. They really are a good company imo.

[Waynio]

Wow, first attempt at metal, I just don't know where to begin with this mighty pat on the back :D, seriously well done man, looks like you have achieved a heck of a lot in life also, respect dude :):up:.

Question though, what do you do with all these awesome mods?, museum of DB :D, auction, charity? or a bit of all 3 8).

[Kayin]

I know he's done the charity thing before. DB gives back, I know that much.

[DarthBeavis]

Wow, first attempt at metal, I just don't know where to begin with this mighty pat on the back :D, seriously well done man, looks like you have achieved a heck of a lot in life also, respect dude :):up:.

Question though, what do you do with all these awesome mods?, museum of DB :D, auction, charity? or a bit of all 3 8).

I have most of them in my house here and there but I do auction off for charity as well. We are doing a charity build at PDXLAN and then another one this Summer.