Project: EVGA Classified SR-2 Case

[Spotswood]

I've been commissioned to build a very large wooden case to house his upcoming watercooled EVGA Classified SR-2 rig. This case is designed and built to run cool, quiet and be ultra-flexible for future upgrades.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/EVGACase2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/EVGACase1.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/EVGACase4.jpg



Note how the side panels are constructed as air ducts for supplying cool fresh air to the front and sides of the case:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/EVGACase3.jpg


The walls will be constructed of 1.5-inch solid oak face frames with 5.2mm oak veneer plywood "panels" bolted to the inside of the frames and with aluminum "adapters" bolted to the front of the panels. The openings in the panels are sized to the largest pieces of hardware envisioned to be mounted in a particular location. The adapters could be exchanged with different adapters depending on what particular hardware is to be mounted in a panel opening.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/EVGACase5.jpg



Here are the specifications and some of the features of this case.


Physical Characteristics:

External dimensions (HxWxD - inches): 44 x 26.5 x 35.5

Materials:

3/4-inch solid red oak, 3/4-inch and 5.2mm oak veneer plywood.
.100-inch aluminum sheet and 1/8-inch aluminum angle, channel and rectangular tube.
1/8-inch clear acrylic.

Features:

The side doors act as air ducts to supply fresh air from the bottom, top and back of the case to the front/sides.
Unique modular panel construction provides flexibility for the placement of drive bays, fans, power supplies, etc.
Mounting locations for two power supplies.
Air flow is: fresh air enters from the side/front and exhausts out the back.
The bottom case has two custom radiator holders for mounting up to four 140x4 radiators.
The case is actually two separate cases bolted together.
Removable ten slot motherboard tray.
Motherboard tray can be mounted in a horizontal or vertical position.
Powder coated aluminum.
Wood finished with black water-based stain and polyurethane.




The bracket to hold the two Black Ice GTX 560 radiators is a simple affair, consisting of some aluminum 1x2-inch square tubing and channel.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/RadBracketModel.jpg

All of the pieces are held together with two long 1/4-inch threaded rods which act as clamps to hold everything together. The ~4mm tall acrylic bumpers get compressed down to ~2mm to keep the radiators in place:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/RadBracketBumper.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/RadBracket1.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/RadBracket2.jpg

All of the aluminum bits will eventually be powder coated gloss black.

[Spotswood]

Some serious real life events have kept me out of the shop most of the week. However, I did manage to create a couple of patterns which I'll use to router out the holes for the 5.25-inch drive bays:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/DriveBayTemplates.jpg


And I built a jig to guide my plunge router to router out the 3/16-inch slots in the 5.25-inch drive bay rails.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/OpticalTemplateParts.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FinishedOptialJig2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/OpticalJigCleat.jpg


A full size drawing is taped to the .10-inch thick aluminum to guide the placement of the jig.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/OpticalRailsAl.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FullSizeDrawingOnAl.jpg


Two sets of stops are used to accurately position the router at the beginning and ending of each slot.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FinishedOptialJig.jpg

[SXRguyinMA]

lookin good! this should be neat :D

[x88x]

I missed this when you started; looks sweet! I gotta admit, when I saw 'EVGA Classified SR-2' and 'cool, quiet', my first thought was, "well, it better have an awesome watercooling system in there, or that's just not gonna happen. :P Those dual 560's look like they should be up the task. ;)

[msmrx57]

OOOOOOOOO! Nice I like wood cases. I'll be watching this for sure.

[Spotswood]

The case can hold four 140x4 radiators, but he's only installing three.

[x88x]

The case can hold four 140x4 radiators, but he's only installing three.

pff! Stupid clients. :P

[Spotswood]

Fabrication of the 5.25-inch drive bay rails continues. After breaking all 3 of my 3/16-inch woodworking router bits I ordered some standard end mills and they have performed awesomely. Because they are run without any lubrication I needed to keep the feed rate really slow.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/RoutingSlots.jpg


After many hours I managed to complete 28 out of the total 35 rails for this case.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/10BayOpticalDriveRails.jpg

[billygoat333]

looking good so far! +rep

[x88x]

Great work on the drive rails. That jig worked out perfectly!

[Spotswood]

Tired of routing all of the 5.25-inch drive rails, I switched to fabricating the PSU(s) mounting plate:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlateModel.jpg


I made a router pattern for 5.25-inch drive cage.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlateOptical1.jpg


And routered out the .10-inch thick aluminum.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlateOptical2.jpg


The round corners were filed square.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlateRoundCorner.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlateSquareCorner.jpg



Another pattern was made for the two PSU mounting holes:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlatePSUTemplate.jpg



Here's the plate (it still needs to be trimmed to its final width):

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlate.jpg

[Spotswood]

Next up were the two internal mounting plates for triple 140mm case fans.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TripleFanPlateModel.jpg


Another aluminum part requires another router template/jig. A 140mm fan was sacrificed for use as a router template:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/140mmFan.jpg


3/4-inch aluminum flat bar was epoxied to the fan frame to keep it nice and square.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/140mmHoleTemplate.jpg

The fan housing was used as a guide to route out yet another full size jig. The jig was placed over a double layer of .10-inch aluminum sheet and routed out with a 1/2-inch flush/pattern router bit.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TripleFanJig.jpg


The finished cuts require zero cleanup (filing/sanding).

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TripleFanPlate.jpg

[Spotswood]

Next up are the bottom mounting plates.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomMountingBracket.jpg


Which requires fab'ing yet another router jig.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomMountingPlateJigFab.jpgG]

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomMountingPlateJig.jpg


The finished result:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomMountingPlate.jpg

Lastly here's a grainy video of me routing one of the 140mm holes:
<object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/k8QVyNRaKpk&hl=en_US&fs=1&"></param><param name="allowFullScreen" value="true"></param><param name="allowscriptaccess" value="always"></param><embed src="http://www.youtube.com/v/k8QVyNRaKpk&hl=en_US&fs=1&" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="425" height="344"></embed></object>

[Spotswood]

Now that I know how wide the widest plate is, the PSU mounting plate was cut to width and mounting holes were drilled.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlatewAMountingHoles.jpg


I'm really proud of how well this turned out.
http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlateCloseUp.jpg


Another plate requires yet another router jig.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/OpticalPlate.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/OpticalPlateJig.jpg


Both plates were routed out of one big sheet because the big sheet is easier to clamp to the workbench.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/OpticalPlateJigInUse.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BothOpticalPlates.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FinishedOpticalPlate.jpg


A test fit:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/OpticalCageMockup.jpg

[x88x]

Looks good. Those sections are coming together great!

[thephreak99]

truly nice work with the router. :)

[Spotswood]

Filed, sanded, scratched and test assembled the 5.25-inch drive rails to the PSUs mounting plate.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlatewRails2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PSUPlatewRails1.jpg

[Spotswood]

Next up are the 5.25-inch drive rails for the four bottom mounting plates.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomRails.jpg


These (unfortunately) required a ridiculous amount of time to complete.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomRailsCU2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomRailsCU.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomPlatewRails.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomMountingPlatewRails.jpg

[Spotswood]

The fan covers are the last of the aluminum parts (yippee!):

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FanCovers-1.jpg


I used a 1/2-inch router bit and an old router template to cut the wiring and tubing slots.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SingleFanCoverRouted.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FanCoverJig.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FanCovers.jpg


Now I just need to (re-)prep everything for powder coating and send them all off to the painter's.

[msmrx57]

For a wood worker you do some very nice metal fabrication. ;) I really like how this is looking.

[Spotswood]

Its time to start making some sawdust!

Ripped and thickness planed some 1x8-inch red oak into 1.5-inch wide boards to be used as the lower case face frames.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FaceFrameMaterial.jpg


Pre-stained the wood and drilled the pocket holes.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PocketHolesDrilledInFaceFrame.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FaceFrameMaterialStainedAndDrilled.jpg


The bottom of the case was also drilled for pocket screws.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomPocketHoles.jpg


Face frames were assembled with some glue and screws.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FaceFrameAssembly.jpg


A homemade depth gauge was fashioned from some rubber stoppers/bumpers.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/HomeMadeDepthGauge.jpg


The depth gauge was used to drill holes for #8 threaded inserts on the inside of the face frames. A hex driver made the task of screwing the inserts into the wood easy.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/ThreadedInsertsDriver.jpg


The lower case face frames and bottom all assembled.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomCaseAssembled.jpg

[x88x]

Nicely done. The black paint makes me bit sad though. I think it's always a shame to cover up the beautiful grains of wood. But, ah well, it's the client's call, I suppose.

[Spotswood]

The top case was built the same way as the bottom.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopFaceFrameMaterial.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopFaceFrameStainedMaterial.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopFaceFrameAssembly.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopCaseAssembled.jpg

[Spotswood]

Powder coating came back this week.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PowderCoating3.jpg


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PowderCoating1.jpg


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PowderCoating2.jpg

[StormRider]

pretty. I approve

[x88x]

Nice finish.

[Spotswood]

Worked on the plywood panels that attach to the frames onto which the aluminum mounting plates are attached.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/InnerSidePanelMaterial.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/InnerSidePanelJig.jpg


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/InnerSidePaneInsidewInserts.jpg


#8 threaded inserts were installed by "pulling" them into the plywood (from the back) by simply screwing in a #8 bolt.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BoltCU.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/InsertCU-1.jpg


The plywood panels are bolted to the inside of the case frame with six stainless steel socket cap screws via threaded inserts.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/InnerSidePanelMountedInsidel.jpg


And the aluminum mounting plates are then bolted to the plywood panels (also with stainless steel socket cap screws) via threaded inserts.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/InnerSidePanelMountedWithPlates.jpg


All of this modularity allows for easily switching to different mounting plates and/or panels in the future.

[x88x]

Nice wood/metal interface there.

[Spotswood]

The back panel of the top case required three router jigs for the PSU mounting plate, 10-slot motherboard tray and 92mm fan holes.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBackPanel.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBackPanel2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBackPanelCU1.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBackPanelCU2.jpg



Rear panel can be rotated for a vertical motherboard mounting orientation.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBackPanelRotated.jpg

[Spotswood]

Another vertical member was added to the opening in the front of the case and the front panel was fabricated just like all the others.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopFrontPanel.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopFrontPanel2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopFrontPanel3.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopFrontPanel4.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopFrontPanelCU.jpg

[msmrx57]

That is gorgeous. :up:

[Spotswood]

The top divider was next.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDividerBack.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDivierFront.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/RoutingTopDivider.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDivider1.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDivider2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDivider3.jpg

[x88x]

Great work as always. Keep it up. :D

[Spotswood]

Cutouts for accessing and viewing the inside of the top case were routed out of the side panels. I was able to re-use two router template jigs for the cutouts, although one had to be mod'd to reduce the width of the cutout.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SidePanelWindowTemplate.jpg

Threaded inserts were installed in order to attach removable plywood covers over the cutouts.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopCaseSidePanelCutouts.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopCaseSidePanelCutoutsCU.jpg


My next task is to build a shelf to fix that droopy motherboard tray.

[Spotswood]

I've been sick all week, but a few days ago I did manage to bang-out a simple support for the motherboard tray.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/MBTraySupport.jpg


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/MBTraySupport2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/MBTraySupport3.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/MBTraySupport4.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/MBTraySupport5.jpg


Ugh, now I need a nap...

[Jolly-Swagman]

Great to hear your well and back at it, coming along awesomely too!

[Spotswood]

I managed to spend a few hours in the shop this morning working on fastening the top divider to the case itself. But just like everything else on this case, nothing is fastened permanently, which meant I needed to install some more threaded inserts.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDividerThreadedInsert.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDivider4.jpg


The divider is attached to the side panel's solid oak rails:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDivider5.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopDivder6.jpg

[Spotswood]

Even the most mundane aspects of a build often require many small steps in order for them to come out just right. For example, in this build the fastening of the side panel covers required having to accurately transfer the locations of several threaded inserts to the covers, which was accomplished by first screwing in some button head screws into the threaded inserts.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopPanlTransferwButtonHeads.jpg

Followed by taping a cover perfectly centered over the cutout. And then using a deep throat clamp, transfer an impression of the button head screw into the backside of the cover.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopPanelTransferwClamp.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/ButtonheadIndentCU.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopSidePanelCovers.jpg

Lastly, with all of the fastening and unfastening of bolts into and out of the threaded inserts, some of them started to become loose. After testing many types of glues, the best method for fixing the loose threaded inserts was to flood the area with Cyanoacrylate glue. Blue painters tape with punched-out holes was used to prevent getting glue everywhere.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopSidePanelCrazyGlued.jpg

[Chiller]

wood is not my taste, i take Thermaltake Level10 case for the SR2 mobo.

but the build, how you make it is nice done.

[Spotswood]

Completed the upper case's bottom.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBottom1.jpg


All holes are 140mm and the covers allow tubing to pass to/from the lower case.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBotomTwo.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBottom3.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBottom4.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopBottom5.jpg

[Spotswood]

I re-assembled the radiator stand. Its simple yet elegant with its industrial kick *** looks.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PCRadStand1.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PCRadStand2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PCRadStand3.jpg

[Spotswood]

I made another router template (the last one for this project!) and cut-out the holes in the bottom case's side panels for the radiator intakes.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomSidePanelCutoutwStand.jpg

[TheGreatSatan]

Purty! +rep

[Spotswood]

I've been working on the case doors, which has been a time consuming task consisting of cutting the 6.2mm-thick oak veneer plywood down to a rough size and then thickening them by gluing strips of 1/2-inch thick birch veneer plywood.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door1.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door3.jpg

The panels are trimmed to their final size (less 1.5-inches) and then 3/4-inch square solid oak strips are glued to the edges of the panels to hide the plywood veneers.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door4.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door5.jpg

[Spotswood]

Any unevenness of the plywood trim was quickly dealt with on the jointer.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door6.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door7.jpg


The doors also function as huge airducts so blocks were glued around the perimeter of the door to offset the door away from the frame of the case.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door9.jpg


The doors are attached to the case via a dead-simple "post and hook" mechanism. The post consists of a #8 socket cap screw, 1/4x1/4-inch aluminum spacer fastened to the case via a threaded insert.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door11.jpg

The hook is a slitted piece of .125-inch aluminum flat bar attached to the blocks on the door via more threaded inserts.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door13.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door10.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door12.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/Door14.jpg

[x88x]

I like the door attachment system. Simple, rugged, and it doesn't look half bad either. ;)

I know I've said this before and I know it's the customer's choice, but every time I see this I can't help but think how beautiful it would look with a nice stain or a urethane sealer instead of the black paint. :(

[Spotswood]

I like the door attachment system. Simple, rugged, and it doesn't look half bad either. ;)

I know I've said this before and I know it's the customer's choice, but every time I see this I can't help but think how beautiful it would look with a nice stain or a urethane sealer instead of the black paint. :(

In person, the black stain looks really good. The wood grain shows through perfectly. I'm thankful he went with the black, because its very easy to hide mistakes. If this case was made out of, say cherry, main-oh-man that would require a ton more time. Whew!

[Starlite KNight]

The black wood makes me think of pianos, but those are glossy. :)

[Spotswood]

With the fabrication of the lower case essentially complete, its on to finishing...sanding, staining and applying wipe-on polyurethane. With a large piece like this, its essential (for me anyway) to be able to apply finishes comfortably, which I can do sitting down by using a homemade turntable.


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomCaseOnTT.jpg


The turntable is just the undercarriage of an old office chair.


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TurnTable.jpg

[x88x]

Hahaha, nice! Great use of a otherwise useless broken chair. :D

[Spotswood]

With the final finish applied to all surfaces the bottom case is now 99% done (its missing the bottom molding, which I won't apply 'til the very end).

Front:
http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomCaseComplete2.jpg


Side:
http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomCaseComplete1.jpg


Top:
http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomCaseComplete3.jpg


Obligatory closeup:
http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomCaseComplete4.jpg

[x88x]

Looks great!

[msmrx57]

Beautiful! I love how you can still see the wood grain.

[Spotswood]

I completed the fabrication of the top case's side doors and attached them using the same "post and hook" latching mechanism that I used on the bottom case.


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/EdgeGlueUp.jpg


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/EdgeGlueUpCU.jpg


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopCaseSideDoors.jpg

[x88x]

O_O ..this thing is going to be ridiculously big isn't it.. :D

[Spotswood]

This week the window in the doors were routed out. Then the doors were scraped, sanded, stained and finished with a satin wipe-on polyurethane finish. Here's what a door looks like after three coats of polyurethane:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopCaseDoorwWindow.jpg

[x88x]

Mmm, shiny. :D

[Spotswood]

In between staining and finishing the parts to the top case, I worked on fabricating the front doors using the same build techniques as all of the other doors in this project. The final width an height of the doors was gradually achieved by numerous trips to and from the jointer.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FrontDoorEdgePieces.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FrontDoorEdgeGlueUp.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopCaseFrameFinished.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FrontCaseWithUnfinishedFrontDoors2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FrontCaseWithUnfinishedFrontDoors.jpg

[cellsite60]

Great build, have not been here for some time and just saw this amazing build.
Keep it up =)

[x88x]

Holycrapthatisalotofclamps! :D

Beautiful craftsmanship.

[Spotswood]

Work on the case continues...

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PowerHole.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BulginSwitch.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PowerHoleBackSide.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/PowerHoleBackSide2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopAndBottomCasesMated2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopAndBottomCasesMated1.jpg

[Spotswood]

Attached the (removable) molding to the bottom of the bottom case.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomMolding.jpg

[Spotswood]

The last bit of fabrication is on the top of the case, made from 3/4-inch oak veneer plywood and solid oak edging. Edging was glued and scraped flush to the surface of the plywood.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopWithEdgeMaterial.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopEdgesGluedAndScraped.jpg


The top is removable. To help with re-aligning the heavy top to the carcass some guide blocks were glued to the underside of the top...

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopGuideBlocks.jpg


...and four threaded inserts were installed.

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/TopThreadedInserts.jpg


http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/BottomOfTop.jpg

[Spotswood]

In the final assembly phase...

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FinalAssembly2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/FinalAssembly1.jpg

[x88x]

Holy balls that thing is huge! I like it. :D

[Spotswood]

Final pics!

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SR2Case1.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SR2Case2.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SR2Case3.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SR2Case4.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SR2Case5.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SR2Case6.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SR2Case7.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/SR2CaseBuilder.jpg

[msmrx57]

Holy hugeness!!!! But it looks great. :up:

[x88x]

Allow me to reiterate:

Holy balls that thing is huge!

I gotta say, the black stain really has grown on me. The finished product is beautiful. :D +rep

Do we get to see it filled up?

[Spotswood]

Allow me to reiterate:


I gotta say, the black stain really has grown on me. The finished product is beautiful. :D +rep

Do we get to see it filled up?

I'll ask the client when I deliver it to him tomorrow. :up:

[SXRguyinMA]

wow! nice work! +rep

we NEED pics of it filled with yummy hardware. tell your client he can't get it unless we all get pics! :D

[Spotswood]

wow! nice work! +rep

we NEED pics of it filled with yummy hardware. tell your client he can't get it unless we all get pics! :D

I know he's running at least three loops through 140x4 radiators, mounted on some custom brackets I built for 'em:

http://i715.photobucket.com/albums/ww153/Spotswood_/EVGA%20Classified%20SR-2%20Case%20Build/RadiatorRack.jpg

[DonT-FeaR]

holy hell i didnt realise it was that huge! very nice

[TheMainMan]

Final product looks phenomenal! Great job.

[Waynio]

Best big case I've seen & it's so perfectly built & nicely finished Spotswood :bowdown:, the picture with you next to it is golden :):up: & I hope your client is paying you well mate ;), already left a comment on bit-tech but doing so here too +rep.

[Spotswood]

Thank you for the comments everyone. Time to move on to some new projects:


http://i715.photobucket.com/albums/ww153/Spotswood_/Custom%20Case%20for%20EVGA%20Dual-Socket%20Board/th_TestStation2_Small.jpg http://i715.photobucket.com/albums/ww153/Spotswood_/Custom%20Case%20for%20EVGA%20Dual-Socket%20Board/th_SimpleDoubleQuadRadCase.jpg

http://i715.photobucket.com/albums/ww153/Spotswood_/Custom%20Case%20for%20EVGA%20Dual-Socket%20Board/th_VorelkCase4b.jpg http://i715.photobucket.com/albums/ww153/Spotswood_/Custom%20Case%20for%20EVGA%20Dual-Socket%20Board/th_SR-2TowerWithRoundedFrontCorners.jpg (http://s715.photobucket.com/albums/ww153/Spotswood_/Custom%20Case%20for%20EVGA%20Dual-Socket%20Board/?action=view&current=SR-2TowerWithRoundedFrontCorners.jpg)