Cygnar Storm Strider Casemod

[monkeyfun]

Sponsors:

Hazard Factory:
http://www.hazardfactory.org/wp-content/themes/scratch/images/masthead.gif
http://www.hazardfactory.org/

Privateer Press:
http://privateerpress.com/sites/all/themes/privateerpress/images/privateer-logo.png
http://privateerpress.com/

Green Fairy Studios
http://greenfairystudios.files.wordpress.com/2011/07/gfstudios_300w.jpg
http://greenfairystudios.wordpress.com/


Greetings!

I am currently embroiled in an epic casemod project, the Cygnar Storm Strider! The Storm Strider is a model available in the Privateer Press game Warmachine. I've decided to make a case in the same vein as the minitature sculptors by casting the individual parts through the lost-foam process.

http://teafromanemptycup.com/casemods/concepts-for-web-storm-stryder01.jpg
http://teafromanemptycup.com/casemods/concepts-for-web-storm-stryder02.jpg
http://teafromanemptycup.com/casemods/concepts-for-web-storm-stryder03.jpg

My planning is ad hoc at best. I’ve got my sizes and plans all jotted out on paper and you’ll probably see my drunken scrawl on the large master documents I have hanging in my basement. But for now here are a few of the details:

- Going to try to keep the case in scale with the dimensions provided in Privateer’s concept art.

- I have to utilize some of the computer parts I already have in my current computer (screw you economy). With no sponsor, this all comes out of pocket and the bulk of my money is going to pay for the scrap aluminum. This means at a minimum I am using:
o my current videocard (a Radeon)
o a spare 500gb HDD
o my current power supply (1000w)
I will probably end up buying:
o mobo - ASAS Maximus Gene-Z - Purchased
o a I-7 2600k (LGA1155) - Purchased
o memory - 16GB DDR3 1600

- This case will stand about 33inches or 84cm tall
- The legs, dome, and lightning coils will be made using the lost-foam casting process.
- I will work this project as though I have a 80 (now 50) day deadline but will continue if I miss it.
For the sake of your bandwidth, I will break up a couple of these posts so I'm not flooding this forum with large pictures.
Now, onto the Creation and Progress!!!
I decided to start with the biggest time sinks for this project... the foam prep for lost-foam casting. There are going to be 4 main part-areas that will be cast in aluminum using lost-foam casting: Legs, Shin plates, Lightning Coils, and the Dome. There might be other pieces and detail parts that I might cast but I'll be creating those as the need arises.

First thing I did was take an image of the actual miniature for perspective shots and the concept art and crop and blow up the images for basic patterns to use. I'm using these as pattern for the shape and general idea of the parts. I did take some artistic liberties and changed some of the depths and design to work with casting and function. Next I started tracing the pattern shapes onto 2" (sorry I'm a backwards American and recorded everything in inches) blue closed cell foam. Then I sketched out and created the base plate onto .25" foam core.

http://teafromanemptycup.com/casemods/foam01.JPG

In the above image you can see my first attempt at creating the coils. I messed around with how I was going to create the coils. I knew I was going to have to create the coils in two parts so that I could properly core the coils for lighting. So I was going to have to have two equal and matching parts that have two unique sides. I originally cut the coil shapes directly out of the blue foam. Then I realized that it was going to be nearly impossible to make the two halves from a single pie. Then I realized it was going be equally difficult making each half match while carving each separately. Finally (and successfully) I was able to create a process for making both halves match by rounding two parts into cylinders at the maximum diameter of each coil. See the stages for both the coils and the legs below:

http://teafromanemptycup.com/casemods/stormstrider/coilprogress01.jpg
http://teafromanemptycup.com/casemods/stormstrider/coilprogress02.jpg
http://teafromanemptycup.com/casemods/foam02.JPG
http://teafromanemptycup.com/casemods/stormstrider/legprogress01.jpg
http://teafromanemptycup.com/casemods/stormstrider/legprogress02.jpg

I’ve been designing the enclosure under the idea that I’d be using a micro-ATX board with my current video card tilted horizontally with a flexible PCI express extender cable. I’ve arranged it so the motherboard location can be moved on the base plate if I go with a different model/brand. I’ve also designed the enclosure to work with any single graphics card that is no bigger than 11”x5”x3.5” and left the possibility to add a second videocard. If I can’t find a suitable/economic replacement, I’ll be using my own graphics card which easily fits within those dimensions. The globe will be cast and either welded or bonded to an aluminum plate cover. The base plate will be made from a single aluminum plate. There will be 4” walls separating the base plate from the cover. These walls are still being designed for their stylization. Here are the progress shots for the mobo plate and top plate:

http://teafromanemptycup.com/casemods/stormstrider/update4/baseplate01.jpg
http://teafromanemptycup.com/casemods/stormstrider/update4/cover01.jpg

As mentioned before the lightning globe will be a cast piece. Basically, I simplified my workload by going to a local craft shop and picking up a 10” white foam flower arrangement globe (the elderly ladies always love it when visit the craft shop, they flirt mercilessly). I bisected the globe and then quartered one half. I cored out the quarters with a dremel trying to maintain a consistent .5” thickness through the wall. As you can see, I also measured and eye-balled the placement of the rings. After I felt comfortable with the look and feel of the ring placement I made basic port-holes in the globe. Next I took some smaller white foam balls and sliced them in half, cored them, then reduced the halves until they made nice little rings. I used regular wood glue (that burned off well in the materials test) to attach the rings to the globe.

http://teafromanemptycup.com/casemods/stormstrider/update4/globe01.jpg
http://teafromanemptycup.com/casemods/stormstrider/update4/cover02.jpg
http://teafromanemptycup.com/casemods/stormstrider/update4/cover03.jpg
http://teafromanemptycup.com/casemods/stormstrider/update4/globe02.jpg
http://teafromanemptycup.com/casemods/stormstrider/update4/globe04.jpg

That’s it for now, I’ll post more tomorrow!

[Fuganater]

Fantastic idea and a great start. Welcome to TBCS! +rep to get you started :D

[ultimatedesk]

Hey man, that's a really great start. Can already see that this is going to have a lot of great small details. Can't wait to see more!

[SXRguyinMA]

Welcome to TBCS! This looks like it's going ot be awesome!

[monkeyfun]

This update is with the lightning coils. The lightning coils are the 3 coiled rods that sit on top of the Storm Strider. I spent time slowly carving and filing away at foam to get a decent shape. There are a couple of things that I’m taking into consideration when I’m sculpting these coils out:

- They don’t need to be too detailed. Most of the details can be added once the coil is cast in aluminum. The aluminum is easier to work while doing minuscule details while the foam is more workable while removing large portions.

- The coil will be hollowed out to be lit up by LED. Because it’s a casemod and what’s the fun of having a case without the lightshow?

- A small bridge might have to be added after the sculpting to allow the molten aluminum to reach all of the points in the mold.

The tools I used to create these foam coils:
- Compass
- Sharpees
- Exacto Blade
- Drywall sanding blocks (2 different grains, fine and very fine)
- Various files
- Dremel
- Foam Magic Wand (a variation of the hot wire, pictured in a previous update)
- Plenty of Painter’s Tape


As stated in the previous update, each Lightning Coil will casted in 2 halves to allow access to the center for lighting. To simplify this process, I took 2 pieces with a center line drawn on both halves and pressed them together over some toothpicks. The toothpicks will give the model a little support when I’m working with them. I draw the maximum radius on both the top and both. Then I trace the outline of the lightning coil on both sides and set latitudes for each peak on the pattern. Next I begin carving down from the highest point trying to keep the circles symmetrical. After the general shapes begin to look right, I start planning out the coils. As you can see below, I’ve had to try several times to make sure the coils lined up and stay in proportion. Eventually I have to brave the point of no return and begin carving out the coil portion.

http://teafromanemptycup.com/casemods/stormstrider/update5/coil02.jpg
http://teafromanemptycup.com/casemods/stormstrider/update5/coil04.jpg
http://teafromanemptycup.com/casemods/stormstrider/update5/coil05.jpg

http://teafromanemptycup.com/casemods/stormstrider/update5/coil07.jpg
http://teafromanemptycup.com/casemods/stormstrider/update5/coil09.jpg

http://teafromanemptycup.com/casemods/stormstrider/update5/coil11.jpg
http://teafromanemptycup.com/casemods/stormstrider/update5/coil13.jpg

http://teafromanemptycup.com/casemods/stormstrider/update6/coilsready01.jpg

This process has taken a bit of time as you have to be careful when sanding and filing foam. If you tear the foam with a file, the foam pieces will cause you to tear more sections of foam. You also have to watch out with the pressure of your hands while hold the foam as that pressure can misshape the model. But the end product is worth it assuming the casting goes well.

Let’s talk about the shin guards. Like I stated before, the shin guards are going to be separately casted pieces from the legs. I’m doing it this way to allow the shin guard to have lighting and to provide hidden wiring access to the shins.

[img]http://teafromanemptycup.com/casemods/stormstrider/update6/shin01.jpg
http://teafromanemptycup.com/casemods/stormstrider/update7/shin04.jpg
http://teafromanemptycup.com/casemods/stormstrider/update7/shin05.jpg
http://teafromanemptycup.com/casemods/stormstrider/update7/shin06.jpg
http://teafromanemptycup.com/casemods/stormstrider/update7/shin07.jpg
http://teafromanemptycup.com/casemods/stormstrider/update7/shin09.jpg
http://teafromanemptycup.com/casemods/stormstrider/update12/shin20.jpg
http://teafromanemptycup.com/casemods/stormstrider/update12/shin22.jpg


The next step is to prepare some of the foam pieces for casting. To do this I need to attach sprues and vents to the pieces to facilitate the casting process.

http://teafromanemptycup.com/casemods/stormstrider/update9/dome07.jpg
http://teafromanemptycup.com/casemods/stormstrider/update9/coil10.jpg

That’s it for now. Next Update I’ll show the casting process!

[mDust]

- A small bridge might have to be added after the sculpting to allow the molten aluminum to reach all of the points in the mold.

*spits out drink*
Wait, what? Metal casting? No way. Let me read that again...


- A small bridge might have to be added after the sculpting to allow the molten aluminum to reach all of the points in the mold.

Holy sh*t! That's awesome! This build is awesome! I have no idea what it actually is, but I know awesome when I see it.


That’s it for now. Next Update I’ll show the casting process!
Please do! If you're doing this at home then you're winning, plain and simple!
Oh, and welcome to TBCS!

[Fuganater]

This just gave me the perfect idea for a mod!

Can't wait to see whats next.

[TheMainMan]

Subbed to this, looks like it will be awesome! Welcome to TBCS.

[monkeyfun]

Casting!

http://teafromanemptycup.com/casemods/stormstrider/update9_5/us01.jpg

I’d like to start this by thanking Rusty Oliver for both teaching me how to cast aluminum and allowing me access to his shop and tools to cast the aluminum. Rusty teaches metal working classes for South Seattle Community College and one of those classes is a casting class. You can also check out Rusty’s work at HazardFactory’s (http://www.hazardfactory.org/) or see him on the TV show Weaponizer (http://www.youtube.com/watch?v=iPl6GvzoOFc).

I’ve broken this process down to three sections; preparing the sand, setting the mould and pouring the metal (aluminum). The pictures and descriptions are from two different casting sessions. We did an initial casting session as a materials test and to test the process. The second session was to make some of the useable parts.

First we had to prepare the sand. When I get into the shop, chances are the sand has been used by a previous class and so I have to break it down the old fashion way with sifter and an old spaghetti strainer.

http://teafromanemptycup.com/casemods/stormstrider/update3/matstest01.jpg

Next I toss all of the sand into an old cement mixer and slowly add water. This makes it so that the sand binds together after it has been placed into a mould and allows it to keep its shape. Unfortunately (or fortunately for your attention span) I don’t have many pictures of me preparing the sand because it’s fairly simplistic manual labor.


The second part of this process is preparing the moulds. Rusty and I spend some time putting together several boxes to hold the sand and the mould for the casting process.

http://teafromanemptycup.com/casemods/stormstrider/update10/makingboxes01.jpg

After the boxes are ready I place the foam parts in the boxes and begin setting sand in and around the pieces to fully enclose the parts. You have to make sure that the sand is packed in fairly tight but not tight enough to distort or damage the foam.

http://teafromanemptycup.com/casemods/stormstrider/update10/sand01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sand17.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sand02.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sand10.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sand03.jpg

After it’s all packed in, you need to uncover the sprues, the vents and make a little trough for the molten aluminum to be poured into.

http://teafromanemptycup.com/casemods/stormstrider/update10/sand19.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sand11.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sandend01.jpg

Here’s that same process with the large half dome piece:

http://teafromanemptycup.com/casemods/stormstrider/update10/sand12.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sand13.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sand14.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10/sandend02.jpg

While we’re preparing the moulds, we are also preheating the furnace and melting aluminum.

http://teafromanemptycup.com/casemods/stormstrider/update10p2/foundry01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/foundry02.jpg

http://teafromanemptycup.com/casemods/stormstrider/update9_5/flames01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update3/matstest03.jpg

http://teafromanemptycup.com/casemods/stormstrider/update3/matstest04.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/melting02.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/melting03.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/melting04.jpg


Eventually we get ready to pour…

http://teafromanemptycup.com/casemods/stormstrider/update10p2/melting06.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/melting07.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/melting08.jpg

But I’ve run out of time, I’ll post the pouring and results tomorrow! Sorry!

[Fuganater]

LOL!!!!

Its like watching a TV show and it has a dramatic ending and now you have to wait until next weeks episode!!!

Its amazing that you have access to that shop.

[mDust]

But I’ve run out of time, I’ll post the pouring and results tomorrow! Sorry!
NOOOOOOOOOOOOOOOOOOOO! lol
That is frikkin awesome, as you know, since you were there.
Don't forget to upload the rest tomorrow. A lot of us are depending on it...it might just be me though. I'm not sure.

Is the furnace just a concrete cylinder with a gas inlet? You know, in case I'm ever forced to build one of my own...:)

[msmrx57]

NOOOOOOOOOOOOOOOOOOOO! lol
That is frikkin awesome, as you know, since you were there.
Don't forget to upload the rest tomorrow. A lot of us are depending on it...it might just be me though. I'm not sure.

Nope, not just you. :D

[DynamoNED]

:eek:

This mod is already so full of awesome and win that I can't make a coherent or intelligent contribution...<slowclap>

Well done, sir, well done. +rep & +subbed.

[TheMainMan]

Arrrggggghhh! This is why I don't watch TV shows during the season! I hate cliff-hangers!
Can't wait to see the rest, the process so far looks super awesome!

[monkeyfun]

LOL!!!!

Its like watching a TV show and it has a dramatic ending and now you have to wait until next weeks episode!!!

Its amazing that you have access to that shop.

Yeah, Rusty is a great guy that like supporting creative endeavors and his shop is like a playground for metal workers.


NOOOOOOOOOOOOOOOOOOOO! lol
That is frikkin awesome, as you know, since you were there.
Don't forget to upload the rest tomorrow. A lot of us are depending on it...it might just be me though. I'm not sure.

Is the furnace just a concrete cylinder with a gas inlet? You know, in case I'm ever forced to build one of my own...:)

The furnace is a home-made concrete refractory with an air-forced propane feed. There's a little more to it than a concrete cylinder. But you can build your own. There are several DIY instructions on the web.


:eek:

This mod is already so full of awesome and win that I can't make a coherent or intelligent contribution...<slowclap>

Well done, sir, well done. +rep & +subbed.

Thank you!


Arrrggggghhh! This is why I don't watch TV shows during the season! I hate cliff-hangers!
Can't wait to see the rest, the process so far looks super awesome!

Thank you! Working on the post now!

[SXRguyinMA]

nice work! hope it turns out well!

[monkeyfun]

Pouring!!!!!!!!

The first pour:

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour02.jpg

Any extra aluminum is poured into ingots to be used later.

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour03.jpg

Before we put the crucible back in the furnace to melt more aluminum we toss in a piece of cardboard to put a little layer of carbon between the furnace and the crucible. This is to prevent the crucible from sticking to the furnace.

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour04.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour06.jpg

The second pour:

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour10.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour11.jpg

This shows the foam burning off. You can also see a little bit of over-run from one of the molds.

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour12.jpg

This is me scrambling to keep the molten aluminum moving off of the concrete floor and cooling it with some sand. Rusty continues pouring more aluminum into the other molds.

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour13.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour14.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p2/pour15.jpg


And for your viewing pleasure, here’s 3 videos covering our pouring experience: us waiting for the aluminum to be ready, pouring, and post pour jitters and conversation.

Waiting:
http://www.youtube.com/watch?v=Y0St6RAslNY

Pouring:
http://www.youtube.com/watch?v=2PjzTrDupBU

Convo & jitters:
http://www.youtube.com/watch?v=jUfD9t-Xjmo

[mDust]

Very impressive!
I know almost nothing about the casting process. The foam burns away to be replaced by aluminum? Unless I'm way off or it's a special clean burning foam, don't bits of burned material get stuck in the casting?
I hope it turned out completely perfect so this mod can get underway.
Also, thanks for the videos. We can't get enough of those around here.:up:

[Fuganater]

Very impressive!
I know almost nothing about the casting process. The foam burns away to be replaced by aluminum? Unless I'm way off or it's a special clean burning foam, don't bits of burned material get stuck in the casting?
I hope it turned out completely perfect so this mod can get underway.
Also, thanks for the videos. We can't get enough of those around here.:up:

That's exactly what I was going to ask!

I can already tell this is going to be very very cool.

[monkeyfun]

Very impressive!
I know almost nothing about the casting process. The foam burns away to be replaced by aluminum? Unless I'm way off or it's a special clean burning foam, don't bits of burned material get stuck in the casting?
I hope it turned out completely perfect so this mod can get underway.
Also, thanks for the videos. We can't get enough of those around here.:up:

When I state that the foam is being burned off technically that is true but it doesn't burn like paper or wood would burn. The foam shrinks from the molten aluminum long before any flame starts. If you want to see what I'm talking about try taking a lit match and move it near some blue/pink home insulating foam. Most of the flames that you see in the pictures above are from the molten aluminum hitting the wooden frame. In one of the moulds, I invested the foam with some plaster and that cause a little be of smoke.

The two biggest concern for bits getting stuck in the casting are impurities in the molten metal from the melting process and sand debris falling from inside the mould. To prevent impurities in the molten aluminum you make a trough for the aluminum to flow into and the cascade over a small barrier into the mould. The impurities go to the low point in the trough while the rest of the molten aluminum flows into the mould. To prevent sand from falling into the mould you just need to balance your moisture content and the packing of the sand.

I'll show you what it looks like when it goes wrong... in the next post. We cast nine piece that day, only 8 were usable. But no more spoilers for now.

[mDust]

But no more spoilers for now.

What if we say 'please'?:)

Thanks for the info as well.

[monkeyfun]

After each pour was done (we did three pours that day), we’d have to let the aluminum cool for at least 10-15 minutes before breaking them out of the moulds.

Cooling pictures:

http://teafromanemptycup.com/casemods/stormstrider/update10p3/cool01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p3/cool02.jpg

I’ll start with the dome. I was worried about this casting. Making the dome took the most effort and will probably need the most work after a casting. It was important to me that these parts came out as good as possible. Here are the results:

http://teafromanemptycup.com/casemods/stormstrider/update10p3/domedone01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p3/domedone02.jpg
http://teafromanemptycup.com/casemods/stormstrider/update10p3/domedone03.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p3/domedone04.jpg

These parts were still extremely hot but very solid. Fortunately, I had the foresight to invest these parts. When the aluminum went outside of the mould, it settled ON TOP of the investment layer. This means that I can remove the extra aluminum and still retain the shape of the intended part (see the last picture).

http://teafromanemptycup.com/casemods/stormstrider/update10p3/domedone05.jpg

The dome halves still retained that white foam texture but I think I can smooth things out with Bondo.

Next we cracked into the small coils:

http://teafromanemptycup.com/casemods/stormstrider/update10p3/smallcoilsdone01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p3/smallcoilsdone02.jpg

Sorry, all of the medium coil pictures ended up being blurry. I was just so excited at the results.

http://teafromanemptycup.com/casemods/stormstrider/update10p3/mediumcoildone02.jpg

Here are the small and medium coils together:

http://teafromanemptycup.com/casemods/stormstrider/update10p3/coilsdone01.jpg

The large coil picture was nice and clear.

http://teafromanemptycup.com/casemods/stormstrider/update10p3/largecoilsdone01.jpg

And now for the disappointment… Every project has its failures. The first attempt at the leg was one of these ‘learning lessons’. When we went to pour for the third time, apparently we ran the furnace too hot for too long. Melt, just like your food, can be over cooked. Over cooking your metal causes funny reactions with other substances, faster oxidation and can cause weird pressure issues inside of the mould. Without being able to see into the mould while we’re pouring I can only assume all of those things happened. You could see the disappointment in my sullen poking of the aluminum corpse. This was the failed results for the leg:

http://teafromanemptycup.com/casemods/stormstrider/update10p3/legdone01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p3/legdone02.jpg

Overall, I learned a little more that Sunday and was very happy with the successful results:

http://teafromanemptycup.com/casemods/stormstrider/update10p3/castingdone01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update10p3/castingdone02.jpg

I hope you didn’t get spoiled with all the pictures, movies and speedy posts. It will be a little bit before I have another significant update as I am waiting for some parts to arrive. But I hope to show the dome on the top cover and the frame work for both the lightning coils and the main enclosure.

[SXRguyinMA]

awesome! +rep

[Yeticorn]

Very impressive indeed, +rep

[xr4man]

wow

[Fuganater]

:stupid:

What they said.

[TheMainMan]

That's so cool!

[monkeyfun]

awesome! +rep
Thank you!


Very impressive indeed, +rep
Thanks!!!


wow
:D


:stupid:
What they said.
Thank you again!


That's so cool!
Thanks!!!


These are only a couple of the parts. Within the next week, I should have some of the pictures of the main enclosure. Then it'll start looking like a computer case rather than a nifty casting project I did.

[monkeyfun]

Finally... the motherboard has arrived:

http://teafromanemptycup.com/casemods/stormstrider/asus01.jpg

I do think it is funny that the big advertising leaflet that came with my LGA1155 motherboard was for AMD processors. Yeah... Including an AMD processor advertising with an Intel motherboard is like trying to sell reading glasses to a blind man.

http://teafromanemptycup.com/casemods/stormstrider/asus02.jpg

Here are both of my new toys: the Gene-Z with the i7-2600k.

http://teafromanemptycup.com/casemods/stormstrider/asus03.jpg


Later today, I am doing some more casting and later this week I'll be fabricating the walls for the main enclosure.

[monkeyfun]

And here's the last bit on my shopping list. I still have to wait until the next paycheck before purchasing but I still have over 1.5 months to get this completed.

------------------------------------------------------------
35 5mm Blue LED
8 100 Ohm resistors
5 220 Ohm resistors

1 White Illuminated Bulgin Style "Latching" Vandal Switch - 16mm - Black Housing - Ring Illumination
2 White Illuminated Bulgin Style "Latching" Vandal Switch - 16mm - Black Housing - Dot Illumination
with Optional Cable Harness used to control any 4-pin molex powered devices.

4 Logisys 4" Cold Cathode Kit (Dual Ready) - Blue
1 4-Channel Inverter-Black4-Channel Inverter-Black

16GB (4 x 4GB) 240-Pin DDR3 SDRAM DDR3 1600 (PC3 12800)
-----------------------------------------

[monkeyfun]

Count Down: Only 39 more days until PAX 2011 (http://prime.paxsite.com/).

The days are counting down faster than I’d like. I’ve had on snag with my casting. I won’t be able to finish casting the legs for another week or two due to scheduling at the shop. This period of stagnation is eating through my modding zen. It’s time to crank up the caffeine and kick this case into gear.

Let’s start things off with some mod stylin’. Remember, if you’re walking down a dark alley behind a computer shop and a bunch of geeks jump you for that sweet videocard you just purchased, just flash your geek sign. Nothing says you’re a hard core geek like TCP/IP.

http://teafromanemptycup.com/casemods/stormstrider/update14/madscientists01.jpg

I like that my bandana is blocking the ‘a’ in ‘mad scientist’. You can almost mistake it for ‘mod scientist’.

This morning I’ve put in my order for some necessary items:

4x - Logisys 4" Cold Cathode Kit (Dual Ready) – Blue
1x - Lamptron 4 Channel High Output Aluminum Cathode Inverter
2x - Blue Illuminated Bulgin Style "Latching" Vandal Switch - 16mm - Silver Housing - Dot Illumination with Latching Switch Cable Harnesses
1x - Blue Illuminated Bulgin Style "Latching" Vandal Switch - 16mm - Silver Housing - Ring Illumination

Hopefully they should be arriving by the end of the week. Once I receive the Cold Cathode tubes I should be able to finish the spine to the point of painting.

But let’s look at some of my other progression.

As you can see here, I’ve drawn a bunch of meaningless stuff on my base plate. Just kidding, I’ve taken my pattern and drawn the respective parts like the motherboard placement, the case walls and posts on the painter’s tape.

http://teafromanemptycup.com/casemods/stormstrider/update14/baseplate10.jpg

Then I cut a bunch of .5” thick aluminum into the same height but varying widths according to what they need to support.

http://teafromanemptycup.com/casemods/stormstrider/update14/posts01.jpg

I also started working on the walls. I am going to try annealing the aluminum walls to bend and create the desired curve in the front of the case. I spent most of yesterday carving out a block of wood to the correct curve for both sides.

http://teafromanemptycup.com/casemods/stormstrider/update14/walls01.jpg

Finally, here’s a picture of the design for the lightning coil spine. It will house all of the wiring and the cathode inverter.

http://teafromanemptycup.com/casemods/stormstrider/update14/spine01.jpg

I’m on a roll so there should be a couple more pictures on the posts, walls and spine in another day or two.

Thanks!

[mDust]

Are you getting a degree or certification in metal fabrication or something? How did you decide to do this? This is just way too far above and beyond the average mod...

[monkeyfun]

Are you getting a degree or certification in metal fabrication or something? How did you decide to do this? This is just way too far above and beyond the average mod...

I wish I had that excuse. I have a weird mix of curiosity and stubbornness. When ever someone tells me I can't do something I figure out how to do it. My wife tells me it is because I'm sassy. I did make a friend who is a metal worker. But like anyone who works in their field they tend to not like holding beginners hands. So, I pick his brain on a couple of things. He talks over my head but I'll grab a word or two. Look those words up and research their processes and then approach him with a couple of quick questions. For the most part, I try to make things as easy as possible for people who do the things I'm looking to learn. I can demonstrate a willingness to learn, to earn the end product, do my homework and research and ply them with the alcohol/coffee/food they want while they're explaining it.

Personally, I'm curious why more people don't do scratch builds or elaborate mods. These things can be ANYTHING you want them to be. Why not go all out?

You might have seen my next: http://www.thebestcasescenario.com/forum/showthread.php?t=26880

I'm currently studying on how to make functioning clock movements so that the case will be fully animated on 12V when I'm done.

I also want to do a XBOX360 mod that is an octopus. I know, weird, but I'm pretty sure I can do it by pouring silicon around extended ports and water cooling insides.

I think my biggest hangup is not having more money to do casemodding with. :redface:

[billygoat333]

haha. Love that last post. And very good filing work... your attention to detail is good :)

[mDust]

I think my biggest hangup is not having more money to do casemodding with. :redface:

That's what sponsors are for. And considering what you've done so far, I'm pretty sure that companies would throw themselves at you if they knew you existed. Introduce yourself to them.

A willingness to learn new things is one of the best characteristics anyone could have. I wish more people in the world had your curiosity and stubbornness 'problem'.

[monkeyfun]

haha. Love that last post. And very good filing work... your attention to detail is good :)

Thanks!!


That's what sponsors are for. And considering what you've done so far, I'm pretty sure that companies would throw themselves at you if they knew you existed. Introduce yourself to them.

Oh, I've been sending out emails. But I think I need to get to a 'more finished' state before I'll see any response as I don't have a body of work to show my commitment or quality of work.


------------------------------------------------

Update #15: Work on the Spine
Count Down: Only 37 more days until PAX 2011 (http://prime.paxsite.com/).

These last few days I have been a slave to the file. I have been filing on the dome to even out some of its pocks and patches. I have been filing on the lightning coils to provide some additional detailing. But this update is about the filing on the spine. I’ve been working on giving my case some tangible shape. Last update I posted the pattern I was working on, now I’ll show it in action. First I cut out 2 pieces of aluminum (1/8” or 4mm thick) using the pattern

http://teafromanemptycup.com/casemods/stormstrider/update15/spine01.jpg

I keyed the two pieces with 2 separate holes and screwed the two pieces together.

http://teafromanemptycup.com/casemods/stormstrider/update15/spine02.jpg

Then, I began filing.

http://teafromanemptycup.com/casemods/stormstrider/update15/spine03.jpg

And filing.

http://teafromanemptycup.com/casemods/stormstrider/update15/spine04.jpg

And filing until the two pieces matched up exactly. Because that’s how we do it when you don’t have a CNC machine to perfectly replicate pieces. :(

http://teafromanemptycup.com/casemods/stormstrider/update15/spine05.jpg

Next, I took a ½” thick 3” wide bar of aluminum and sliced off pieces for the frame of the spine. The front piece will be filed to fit exactly in the front.

http://teafromanemptycup.com/casemods/stormstrider/update15/spine06.jpg

http://teafromanemptycup.com/casemods/stormstrider/update15/spine07.jpg
Since the 4” Cold Cathode Ray tubes are being shipped to my location, I did some more clean-up work on the lightning coils themselves. The tubes will be inserted inside of the coils. For the clean-up work, I utilized my trusty Dremel.

http://teafromanemptycup.com/casemods/stormstrider/update15/spine08.jpg

But sometimes, the little Dremel just won’t cut it and I have to break out with the Roto-Zip.

http://teafromanemptycup.com/casemods/stormstrider/update15/spine09.jpg

Assuming the 4” Cold Cathode Ray tubes and not 4.5” or 4.8” I verify that I’ll be able to fit the tubes and their wiring inside of the spine.

http://teafromanemptycup.com/casemods/stormstrider/update15/spine10.jpg
http://teafromanemptycup.com/casemods/stormstrider/update15/spine11.jpg
http://teafromanemptycup.com/casemods/stormstrider/update15/spine12.jpg

Once I make sure, the tubes fit in both the coils and the spine, I’ll seal the coils and make sure they have enough space to shine and there’s no pressure on the tubes from the aluminum. The last thing I want is a cathode tube bursting in transport or setup.

We’ll that’s it for today. I should be able to completely finish the construction of the spine and coils after the tubes arrive. I have to wait until Friday before I can continue on the main enclosures as I have to pick up a plumber’s torch, more dremel wheels, and some cold chemical weld. Until then I guess I’ll start working on the lower enclosure.

Thanks for reading!

[CorsePerVita]

Man this is crazy stuff. I've seen people cut stuff before, but never seen anyone pour stuff out of molds like this. AND showing the process is pretty rad! Very cool man! I can't wait to see it all assembled and put together. This is going to be awesome!

[monkeyfun]

Arrived last night!:

1 White Illuminated Bulgin Style "Latching" Vandal Switch - 16mm - Black Housing - Ring Illumination
2 White Illuminated Bulgin Style "Latching" Vandal Switch - 16mm - Black Housing - Dot Illumination
with Optional Cable Harness used to control any 4-pin molex powered devices.

4 Logisys 4" Cold Cathode Kit (Dual Ready) - Blue
1 4-Channel Inverter-Black4-Channel Inverter-Black

Picking up today:

16GB (4 x 4GB) 240-Pin DDR3 SDRAM DDR3 1600 (PC3 12800)
Dremel EZ-lock Wheels
Plumber's Torch
Cold Weld stuff

Arriving later this week:
PCI-Express 2.0 x16 Flex Riser 5"



Only thing left on my shopping list:

35 5mm Blue LED
8 100 Ohm resistors
5 220 Ohm resistors

& Paints!

[CorsePerVita]

Pics moarrrrr pics! :)

[monkeyfun]

Update: Still alive and working!
Count Down: Only 31 more days until PAX 2011 (http://prime.paxsite.com/).

In the back of my mind, there is a certain amount of panic setting in… I only have 31 more days and I’m still making parts. I think many of my fears will be alleviated when I’m actually assembling the case rather than devilling the details.

But I got toys!!!!

http://teafromanemptycup.com/casemods/stormstrider/update16/toys01.jpg

I am now able to proceed with the lightning coil creation!

http://teafromanemptycup.com/casemods/stormstrider/update16/toys02.jpg

And the PCI Express x16 Flexible riser has arrived!!! I can now proceed with the video card placement.

http://teafromanemptycup.com/casemods/stormstrider/update16/toys03.jpg

I borrowed an idea from something I saw on Nhenhophach’s ROG Rampage scratch build. I’ll be utilizing the motherboard’s mounting screw holes to create a platform to hold my video card. I’ll post more on this process and implementation later for now all you get is the plate I cut for it.

http://teafromanemptycup.com/casemods/stormstrider/update16/vidcardplate.jpg

Next, I began working on the main two walls of the main enclosure. I started by making a minor cut in the aluminum to help fold wall. This helps you bend the aluminum to the desired angel.

http://teafromanemptycup.com/casemods/stormstrider/update16/wall01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update16/wall02.jpg

http://teafromanemptycup.com/casemods/stormstrider/update16/walls03.jpg
http://teafromanemptycup.com/casemods/stormstrider/update16/walls04.jpg

Next, I decided I didn’t want to wait to get access to the machine shop to anneal the aluminum. So, I went down to the local hardware store and picked up a plumber’s torch. The packaging says the temperature can reach up to 2100 degrees Fahrenheit which is more than adequate for annealing the aluminum. (Annealing the aluminum makes the aluminum soft so it can be bent over a curved shape and retain that shape.)

http://teafromanemptycup.com/casemods/stormstrider/update16/walls05.jpg

Unfortunately, the torch is too small. Every time I’d start to heat up one part of the aluminum the torch would run out of butane. I was defeated.
I will have to wait until I can get into the shop. So I traded the plumber’s torch for a different toy!

http://teafromanemptycup.com/casemods/stormstrider/update16/toys04.jpg

I have also worked on the framing for the case. I started off with an shape… and then relented to simpler C shape.

http://teafromanemptycup.com/casemods/stormstrider/update16/walls06.jpg

http://teafromanemptycup.com/casemods/stormstrider/update16/walls07.jpg

I’ve made some progress with the coils. Since I received the cathode tubes I was able to test-fit the tubes to the coils. With that completed, I started cleaning up and assembling the coils. First I broke them down to their parts by removing any excess aluminum sprues. As you can see each coil broke down into 4 parts… except for the smallest coil because I didn’t notice one coil not completely attached to either coil cap or the base.

http://teafromanemptycup.com/casemods/stormstrider/update16/coils01.jpg

Fortunately, I’m just working with a giant miniature and I can use the same techniques used for modeling those figures. I can ‘pin’ the pieces together to give it stability. Matter of fact, I even use Privateer Press’s P3 model glue to do the trick. For pins, I’ve simply snipped up an old wire hanger.

http://teafromanemptycup.com/casemods/stormstrider/update16/coils02.jpg

http://teafromanemptycup.com/casemods/stormstrider/update16/coils03.jpg

That’s all for now. Soon I’ll be working completing the coils, removing the part separation lines, annealing the case walls, and casting the legs. So much to do… so little time.

[monkeyfun]

Update #17: Kerfing works!
Count Down: Only 28 more days until PAX 2011 (http://prime.paxsite.com/).

In exactly 4 weeks at the time I’m writing this (7am local time), I will be standing in a line waiting for my coffee so I’ll have something to drink while I’m standing in line waiting to set up my computer so I can stand in line later in an exhibition hall at PAX.

Standing in line, it’s a hobby.

My impatience decided that waiting for shop access wasn’t conducive to forum update and my sanity. I decided to give kerfing a try. I started off with marking off all of the cut lines.

http://www.teafromanemptycup.com/casemods/stormstrider/update17/wall10.jpg

Then I simply used my dremel to make small groves in the metal. With the assistance of a rubber mallet, I bent the metal into a curve.

http://www.teafromanemptycup.com/casemods/stormstrider/update17/wall11.jpg
http://www.teafromanemptycup.com/casemods/stormstrider/update17/wall12.jpg

My curve is a little off. But I will re-work it to a better curve. I set up the wall with the posts.

http://www.teafromanemptycup.com/casemods/stormstrider/update17/wall13.jpg

The second wall turned out MUCH better. Fortunately, this is metal and you get second chances as long as you’re not cutting things out.

http://www.teafromanemptycup.com/casemods/stormstrider/update17/wall14.jpg

Next I set up a couple of the pieces to get an idea of how it is all coming together. :) I’m feeling pretty good about the case so far.

http://www.teafromanemptycup.com/casemods/stormstrider/update17/wall15.jpg
http://www.teafromanemptycup.com/casemods/stormstrider/update17/wall16.jpg
http://www.teafromanemptycup.com/casemods/stormstrider/update17/wall17.jpg

The lightning coils are ready for their putty then clean up. I’ve tested the tubes inside of the coils and they look awesome… of course, you’ll have to wait to see that.

http://www.teafromanemptycup.com/casemods/stormstrider/update17/coils30.jpg

That’s it for now! I should have some more pictures and updates after the weekend.

[SXRguyinMA]

looking good!

[xr4man]

this is just full of awesome!

[monkeyfun]

looking good!

Thank you!


this is just full of awesome!

That is my goal, good sir.

[monkeyfun]

Just a quick little update, the voting has been closed on Privateer Press's forums. I will be sacrificing a miniature to the furnace. Nemo was selected by the masses:

http://www.brookhursthobbies.com/images/products/standard/PIP31021.jpg

It's nice to see the Privateer Press enthusiast get excited about this project. I've even gotten a couple of requests to come by and see the case at PAX. Fun times!

[monkeyfun]

I have some REALLY exciting news! Privateer Press is going to provide me with the paints I need to paint this case! I have my first sponsor! I am working out how they want me to list their sponsorship and have provided them the paint colors and quantities I need. As an added bonus, they will be featuring this case in their monthly magazine which has an international readership!

*swoon*

If you'd like to know more about Privateer Press, just check out some of the games they have! If you play these types of games, I suggest playing Grind and Warmachine! They're two games I love to play and of course influenced my decision to do this case.

http://privateerpress.com/


Thank you very very much Privateer Press! I love it when the excitement and awe is contagious!

[SXRguyinMA]

congrats!!

[TheMainMan]

Great to see sponsors taking interest, your work deserves it!

[Notyab]

That is amazing work. I wish i had the time and resources to do something fun like this. Great work man :)

[dooglo]

This is simply just awesome. Great work. Love the craftsmanship your showing all of us.

Keep it up.

D.

[monkeyfun]

congrats!!

:banana:


Great to see sponsors taking interest, your work deserves it!

Thanks!!! I appreciate any and all the help I can get.


That is amazing work. I wish i had the time and resources to do something fun like this. Great work man :)

Actually, so do I. I'm working 2 jobs, doing this case mod and planning two others (a clockwork DVR and a My Little Pony case). As for resources, I've been doing this all on the cheap. I buy scrap aluminum plates for framing. The aluminum I'm melting down is scrap from local bicycle shops (wheel rims and some frames are aluminum). My biggest expense was buying the computer parts.


This is simply just awesome. Great work. Love the craftsmanship your showing all of us.

Thank you every much.

[Snowman]

are the pictures in post 41 dead for anyone else?

[monkeyfun]

are the pictures in post 41 dead for anyone else?

Yeah, it looks like Yahoo Business Hosting is having some trouble. I'm getting a hold of them and seeing what's going on.

I'm getting dropped connections when attempting to connect to the server.



--------------------------------


Looks like there might have been some problems with the A record for my domain hosting. Hopefully the quick little work around works until they get it figured out. Try refreshing the page and see if it comes through now.

[monkeyfun]

When it rains, it pours!

I might have a second potential contributor/sponsor!

Details will be posted soon with an actual update!

[monkeyfun]

Update #18: Paint and Tapping Frustrations
Count Down: Only 23 more days until PAX 2011 (http://prime.paxsite.com/).

Look what arrived! First off I’d like to thank my new sponsor. Privateer Press! For those of you unfamiliar with Privateer Press they make a several fun games and a line of paints. The idea for the model was derived from one of their Battle Engines from the game Warmachine.

http://privateerpress.com/sites/all/themes/privateerpress/images/privateer-logo.png
http://privateerpress.com/

Not only did they agree to sponsor me but they sent their help in record time. A package arrived on my door step by the time I finished reading the email saying they’d sponsor me. It was filled with four cool looking boxes.

http://teafromanemptycup.com/casemods/stormstrider/update18/pppackage01.jpg

Each of those boxes were filled with model paints! And they sent two cool patches to use for a process display!

http://teafromanemptycup.com/casemods/stormstrider/update18/paints04.jpg

http://teafromanemptycup.com/casemods/stormstrider/update18/paints02.jpg
http://teafromanemptycup.com/casemods/stormstrider/update18/paints01.jpg

The colors I requested and they provided were:
Exile Blue, Cygnar Blue Base, Cygnar Blue Highlight, Arcane Blue, Menoth White Highlight, Morrow White, Thamar Black, Battlefield Brown

http://teafromanemptycup.com/casemods/stormstrider/update18/paints03.jpg

I should be able to use these colors to replicate the colors they used for the gallery entry for the Storm Strider:

http://teafromanemptycup.com/casemods/concepts-for-web-storm-stryder02.jpg

All in all, this help from Privateer Press brings me to a new level of happiness and excitement! I can’t wait to try out all of the new stuff. Even better news, I’m in discussions with D. Anthony over at Green Fairy Studios. They would like to help out the project by painting and/or detailing the case! As time runs short, this is a much needed boost to my confidence and my ability to make the PAX deadline! Feel free to check out his work: http://greenfairystudios.wordpress.com/

http://greenfairystudios.files.wordpress.com/2011/07/gfstudios_300w.jpg

Now, back to the case! I am all tapped out. Literally, I am out of taps. I ran into a bit of a snag and snapped not one but two of my taps. Fortunately, I was able to extract the snapped pieces without damaging any of the pieces. Do any of you experience metal workers out there have any advice for me? Am I just strong arming my taps? They are kind of thin/small, 4-40 taps. Is there a brand anyone prefers?

Here’s the base plate with half of the posts attached.

http://teafromanemptycup.com/casemods/stormstrider/update18/plate20.jpg

I’ll probably have another post on Friday/Saturday. Stay Tuned!!

[xr4man]

my only advice is to only turn the tap about a 1/4 turn at a time. backing it off after every 1/4 turn and then every couple of full turns backing it all the way out to get the metal shavings out of the hole.

perhaps you used a slightly too small drill bit to make the initial hole?

[monkeyfun]

my only advice is to only turn the tap about a 1/4 turn at a time. backing it off after every 1/4 turn and then every couple of full turns backing it all the way out to get the metal shavings out of the hole.

perhaps you used a slightly too small drill bit to make the initial hole?

The drill bit i used was included in the tap package as the 'matching drill bit'. It's probably me just being too aggressive or not clearing enough shavings out.

[xr4man]

well i guess that's the right drill bit then.

[Commando]

Absolutely amazing project.... I'll def be following this one till the end...

TD

[monkeyfun]

Absolutely amazing project.... I'll def be following this one till the end...

Thank you!

--------------------------------------------------------------------------


As a little update:

Do not be surprised if every single mod I do for the next 10 years has blue LEDs. I just got a screaming deal from a US LED manufacturer: 1000 Blue LEDs for $27 USD.

Even if 950 of them don't work, I'll still have enough for this project and will have paid less than buying them from the local Radio Shack.

[msmrx57]

Do not be surprised if every single mod I do for the next 10 years has blue LEDs. I just got a screaming deal from a US LED manufacturer: 1000 Blue LEDs for $27 USD.

Even if 950 of them don't work, I'll still have enough for this project and will have paid less than buying them from the local Radio Shack.

You could always sell some of the extras here. Just sayin.

[monkeyfun]

You could always sell some of the extras here. Just sayin.

You can do that? Hmmm...

[msmrx57]

http://www.thebestcasescenario.com/forum/forumdisplay.php?f=134

[monkeyfun]

Update #19: Main Enclosure
Count Down: Only 18 more days until PAX 2011 (http://prime.paxsite.com/).

TICK TOCK TICK TOCK TICK TOCK

Yes, I hear the clock’s deafening roar. But no, I am not worried. My goal is to have it done by PAX (August 26th), although if that doesn't happen I will still be diligently working on it until completion.

In all honesty I am hopeful that I will have it completed on time but... it all comes down to what happens on August 9th. I am casting the master pieces of the legs on the 9th. IF they turn out good then I'll be able to do a second casting later that week and the pieces from the 9th as masters and replicate one leg into four. Those four legs will need to be cleaned up and put everything together. But all of the cleaning parts and the assembly can happen at "midnight on 8/25" and I'd still have a showable piece.

IF they don't turn out as usable pieces, then I have to carve more pieces out from foam and recast them which will take quite a bit more time. Absolute worst case scenario, this project will be completed in October at the latest.

Best case scenario, it's completed on time. Now, onto the update!


Allow me to introduce you to Nemo. Nemo has a very short time to live. He has until August 9th and then he will become one with the casemod. To all of those that participated in the voting to pick which model was going to be melted down and infused with the casting, thank you. To those of you that requested that I use the old Nemo rather than the 2010 model, I apologize. I was only able to obtain a 2010 model in this short notice. Wish Nemo well because his life will not be long.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/nemo01.jpg

I finally got all of the enclosure posts completed.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate21.jpg

Then I began attaching the walls.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate22.jpg

After each wall was attached, I made sure they fit properly and filed down any parts that over lapped the edging.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate23.jpg

Here is a front view before I filed down the front edge.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate24.jpg

Here is a close up of that front edge and the curve.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate25.jpg

This was one of the broken taps I had mentioned… I was able to extract the tap by simply unscrewing the tap from the post.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate26.jpg

I was able to put all of the mother board mounting posts into the base plate.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate27.jpg

I finally attached the back plate to the posts.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate28.jpg

The enclosure has finally taken shape. I can’t tell you what a relief it is to see your mechanizations take shape when they’ve only been figments of your mind and snippets of conversation. It is a validation. Oh, just to the right is Nemo. He’s over-seeing the construction and screw inventory/count.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate29.jpg

I tossed the template into the enclosure to get an idea of placement and to make sure the motherboard mounts will work. It wasn’t until that day did I even notice the template piece I have been using was for a Maximus III rather than the Maximus IV. After a little bit of panic and double checking with the actual board, the template works for aligning the motherboard mounting holes.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate30.jpg

Next I file off the extra bits for the back plate. I’ll do the same for the top after I place the top plates.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate31.jpg

Then I place the top plates. I cut these plates using the base plate as a template… which was a mistake.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate32.jpg

Since I’m making this whole case ad-hoc, there are little difference between posts and how things align. The parts aren’t exactly symmetrical but they are functional and aesthetically decent. That being said, I cut the top pieces too early and now they don’t fit with the top part of the posts. The right side would be off on one of the inside walls. The left side is a little too short.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate33.jpg

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate34.jpg

So, I decided to just cut two new pieces. I’ll start on the top plate details after I cast the center piece and attach the two inside walls.


http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate35.jpg

Since I can’t work on the top plate until after the casting, I started working on the windows. There will be a fan on each side to help with air flow in the case.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate36.jpg

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate37.jpg

Here is a quick look at the mesh I’ll be using in the windows.

http://www.teafromanemptycup.com/casemods/stormstrider/update19/plate38.jpg

Well… I hate to leave you with that gnarly, unfiled window cut but that is it for now. Another update will be posted later this week. We’ll see if I can get the windows completed and the next set of casting pictures up in the next update. Thanks for reading!

[monkeyfun]

Ok, we did the casting of six pieces last night. These are all the pieces needed to repilicate into 3 other legs. Aaaaaannnd I still have to process all of the pictures and the movies. The result?

I have good news and bad news.

[monkeyfun]

Still working on the update. To keep you entertained...

http://teafromanemptycup.com/casemods/stormstrider/update20/nemo01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update20/nemo02.jpg

RwXX1dXVpqE
http://www.youtube.com/watch?v=RwXX1dXVpqE

[SXRguyinMA]

RwXX1dXVpqE :D

[monkeyfun]

Update #20: More Casting! Good news and bad news.
Count Down: Only 15 more days until PAX 2011 (http://prime.paxsite.com/).

http://www.hazardfactory.org/wp-content/themes/scratch/images/masthead.gif
HazardFactory’s (http://www.hazardfactory.org/)

First off, I’d like to thank Rusty @ HazardFactory for all of the help and the use of his shop. Without his help, this project simply would not be. Rusty:
http://teafromanemptycup.com/casemods/stormstrider/update20/rusty01.jpg


Like the previous work log entries before, I had to prepare the sand and each of the moulds.

http://teafromanemptycup.com/casemods/stormstrider/update20/prep01.jpg

The furnace had to be heated up and aluminum melted.

http://teafromanemptycup.com/casemods/stormstrider/update20/furnace01.jpg

The Furnace
bJSmt7C23CA
http://www.youtube.com/watch?v=bJSmt7C23CA

http://teafromanemptycup.com/casemods/stormstrider/update20/wholeprocess01.jpg

Melting Video
JtX4kj9I3cs
http://www.youtube.com/watch?v=JtX4kj9I3cs

Then of course, we poured the aluminum:

Pouring part 1:
Q0-Kq-OEmRw
http://www.youtube.com/watch?v=Q0-Kq-OEmRw

Pouring part 2:
yDdI6RvzweM
http://www.youtube.com/watch?v=yDdI6RvzweM

After pouring we waited about 20-30 minutes then checked our work:

Reveal part 1:
HoH5pwmER4U
http://www.youtube.com/watch?v=HoH5pwmER4U

Reveal part 2:
3JJBmWqGyDc
http://www.youtube.com/watch?v=3JJBmWqGyDc


http://teafromanemptycup.com/casemods/stormstrider/update20/castingresults01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update20/castingresults02.jpg

http://teafromanemptycup.com/casemods/stormstrider/update20/castingresults03.jpg

http://teafromanemptycup.com/casemods/stormstrider/update20/castingresults04.jpg

http://teafromanemptycup.com/casemods/stormstrider/update20/castingresults05.jpg

Oh! The LEDs arrived. If you were curious, this is what 1000 LEDs look like:

http://teafromanemptycup.com/casemods/stormstrider/update20/leds01.jpg


The Good News: These castings are great! 5 out of the 6 parts will require minimal additional work and that 6th part is usable after a little repair work. These parts can be used for master parts to do impressions to cast the other legs.

The Bad News: I won’t be able to use the shop again until September/October. This means I won’t be able to cast aluminum. The shop I have been using by the grace of Hazard Factory has a series of paying projects that will be taking up the space and time. I appreciate all of the help Hazard Factory has provided so far and look forward to working with Rusty again in the future. With what I currently have cast, I still need to do 11 more parts. So… this means I won’t be finished in time for PAX. :(


However, all hope is not lost. I have a plan. I will teach myself resin casting and see if I can make aluminum framed and re-enforced resin legs. I can do that this next weekend, right? I will need to make a three-part plaster mould for the shin guard and two two-part moulds for the legs. I’ll pick up the resin this Friday and begin the work ASAP.


Like I said at the very beginning of this project, even if I don’t get it completed by PAX, I will still be completing this project. I will even bring the partially completed project to PAX as the main enclosure will be assembled and usable as a computer case. It’ll either be missing the legs or have armature legs holding it up.

Still not losing momentum! Mod on my friends!

[billygoat333]

That is awesome! love the use of casting!

[mDust]

I love the videos! I wish I could have been there to see the whole melting and casting process. It sucks that the shop has to kick you out for a bit, but a lot of people here have experience with resin (myself not included), so ask away if you have questions.

[monkeyfun]

I love the videos! I wish I could have been there to see the whole melting and casting process. It sucks that the shop has to kick you out for a bit, but a lot of people here have experience with resin (myself not included), so ask away if you have questions.

Yeah, I was a little let down that the shop was unavailable this month, but I'm counting my blessings rather than disappointments. They have already basically donated about $1700 in time, labor and space rental towards this projects. And for that I am grateful. It's up to me now to find and make an alternative work if I want to get this done by PAX.

I spent 5 hours last night cleaning up the newly cast pieces and I should be able to make the moulds this weekend. I've pretty much have to hustle on all of the parts. Anthony @ Green Fairy Studios said he'd paint the whole case for me, if I can get the parts to him to paint on the 20th/21st of August. I predict many long hours this weekend and next week.

[monkeyfun]

Update #21: Mould Making.
Count Down: Only 11 more days until PAX 2011 (http://prime.paxsite.com/).

I've finished cleaning up the parts I recently cast. It's a little rough but beggars can't be choosers when you're trying to make a time-line. In hind sight, I'm thinking I should have started this project about 2 months earlier. Regardless, here's the parts placed together:

http://teafromanemptycup.com/casemods/stormstrider/update21/leg01.jpg

Next, I made connecting parts and place holders for both the mould and where the wire tube is going to be. Then I attached the parts with a regular glue gun. I used a glue gun because I wanted them to hold together for the casting but easy enough to pry apart.

http://teafromanemptycup.com/casemods/stormstrider/update21/leg03.jpg

http://teafromanemptycup.com/casemods/stormstrider/update21/leg02.jpg

Then I made a box to create the mould in... it's big enought for both the leg and the shin guard.

http://teafromanemptycup.com/casemods/stormstrider/update21/mould01.jpg

http://teafromanemptycup.com/casemods/stormstrider/update21/mould02.jpg

To be extra careful I coated the box seems in Vaseline and then did a light coat of baby powder (talc). This is to keep the plaster from sticking to the box. I also coated the leg with Vaseline.

http://teafromanemptycup.com/casemods/stormstrider/update21/mould05.jpg

http://teafromanemptycup.com/casemods/stormstrider/update21/mould04.jpg

The leg was suppended in the middle of the box.

http://teafromanemptycup.com/casemods/stormstrider/update21/mould03.jpg

NExt I filled the box half way up with plaster.

http://teafromanemptycup.com/casemods/stormstrider/update21/mould06.jpg

After the plaster dried, I made three key holes so the two halves of the mould could be fitted back together. Then I coated the top half of the mould with Vaseline and poured the second half of the plaster.

http://teafromanemptycup.com/casemods/stormstrider/update21/mould07.jpg

http://teafromanemptycup.com/casemods/stormstrider/update21/mould08.jpg

The mould came out pretty good considering I haven't made a plaster mould in 16 years. There will be some rough edges when I do the resin casting but all in all I should be able to sand and clean up finished product.

http://teafromanemptycup.com/casemods/stormstrider/update21/mould09.jpg


As a side note... if you're making a mould of this size it's unadvisable to buy the 3 pound box when you need 50 pounds of plaster... lessons learned.

http://teafromanemptycup.com/casemods/stormstrider/update21/plaster01.jpg

Next update in 2 days.

[monkeyfun]

Update #22: The Enclosure.
Count Down: Only 10 more days until PAX 2011 (http://prime.paxsite.com/).

I need elves …like those little elves that make shoes for the cobbler… someone to work on my case while I’m at work. :|

The case enclosure has shape!!! Here’s a picture with all the walls in. I still have some more cleaning up to do and filing around the edges but I wanted to get things put together to make sure I didn’t have any design flaws that would keep the parts from fitting.

http://teafromanemptycup.com/casemods/stormstrider/update22/enclosure01.jpg

Each of those panels will end having mesh put into them… but that’s in the future, near future hopefully.

http://teafromanemptycup.com/casemods/stormstrider/update22/enclosure02.jpg

Next I began fitting the cover plate. Since I ended up cutting new pieces (see update #19) I had to file down all of the overlapping parts.

Before:
http://teafromanemptycup.com/casemods/stormstrider/update22/enclosure03.jpg

Half way:
http://teafromanemptycup.com/casemods/stormstrider/update22/enclosure04.jpg
Much better:
http://teafromanemptycup.com/casemods/stormstrider/update22/enclosure06.jpg

Here’s an unfocused over-view of one half. I apologize for the quality of this picture but… I’d rather rush a picture or tow than not get any for the work log.

http://teafromanemptycup.com/casemods/stormstrider/update22/enclosure05.jpg

Here’s a view of the over lapping parts and the mismatched rear-arch.

http://teafromanemptycup.com/casemods/stormstrider/update22/enclosure07.jpg

After I did some filing on the rear-arch:
http://teafromanemptycup.com/casemods/stormstrider/update22/enclosure08.jpg

I had to stop here as I needed to use the table saw to cut some pieces and my neighbors frown on metal cutting at 11pm in the evening. More pictures will be up in 2 days. Tonight repairing some of the casting flaws with bondo, attaching the dome to the top piece, tapping the frame for the lightning coil spine, cutting the pieces for the PSU/HDD enclosure, cutting the frame for the leg resin pieces and cutting the holes for the input/output ports in the back panel. Tomorrow, I’ll clean up the plaster moulds a little bit and make a stab at the resin casting.

[monkeyfun]

Update #23: The Mad Dash.
Count Down: Only 9 more days until PAX 2011 (http://prime.paxsite.com/).

I know I said I was going to update every two days but I got a bit done last night and … well… you’ll see.

Completed Last night:

Prepared the cover plate for cutting
Repaired some of the casting flaws with bondo
Cold welded the lightning coils seams for stability
Tapped the frame for the lightning coil spine
Assembled lightning coil frame
Cut out Frame pieces for leg resin
Cut wire tubing for legs
Cut out Mesh pieces for side walls
Cleaned up the plaster moulds

Pictures:

Prepared the cover plate for cutting:
http://www.teafromanemptycup.com/casemods/stormstrider/update23/cover10.jpg

The mesh is ready!
http://www.teafromanemptycup.com/casemods/stormstrider/update23/mesh01.jpg

Here are the wiring tubes and the leg frames.
http://www.teafromanemptycup.com/casemods/stormstrider/update23/mouldparts01.jpg
http://teafromanemptycup.com/casemods/stormstrider/update23/mouldparts02.jpg

This was all the work that I completed on the spine:
http://www.teafromanemptycup.com/casemods/stormstrider/update23/spine01.jpg
http://www.teafromanemptycup.com/casemods/stormstrider/update23/spine02.jpg
http://www.teafromanemptycup.com/casemods/stormstrider/update23/spine03.jpg
http://www.teafromanemptycup.com/casemods/stormstrider/update23/spine04.jpg
http://www.teafromanemptycup.com/casemods/stormstrider/update23/spine05.jpg

And finally for this update you can see a semi assembled case!!! Please forgive the pink lightning ports. I’m smoothing those parts out with bondo.

http://www.teafromanemptycup.com/casemods/stormstrider/update23/together01.jpg

http://www.teafromanemptycup.com/casemods/stormstrider/update23/together02.jpg

What’s left? Here’s the To-Do list I have until the case is completed.

To-Do list:
Cold weld Wire tubes to resin leg frame
Cut the pieces for the PSU/HDD enclosure
Create frame and enclosure mounts for the PSU/HDD enclosure
Cut out switch holes on PSU/HDD enclosure
Assemble PSU/HDD enclosure
Cut the holes for the input/output ports in the back panel
Create cover pieces for the spine
Attach lightning coils to spine
Cut Spine attachment pieces
Cut spine space and panels out of top cover plate
Cut out wiring holes in main enclosure base plate
Bend and insert mesh pieces to side walls and top cover plate
Cold weld dome to cover plate
Cast resin legs
Attach legs to PSU/HDD enclosure
Create 3 part mould for shin guards
Cast resin shin guard
Attach shin guard
Cut acrylic windows for all lightning ports
Wire shin guards for LED lighting
Base paint all the parts
Paint the case
Insert the video card mounting plate
Put in all of the hardware and switches
Test run for shorts and issues
Disassemble case for transport


Next update will be in 2 days at latest.

[SXRguyinMA]

this thing just gets more and more impressive!

[monkeyfun]

this thing just gets more and more impressive!

Thank you! I'm slowly but surely crossing things off my list... soon... soon I'll be complete.

[Snowman]

wish I knew why the pictures never load for me....

[monkeyfun]

wish I knew why the pictures never load for me....

Try reloading the latest update again. I keep forgetting that some people might have difficulties if the picture urls don't have the www. listed. It's pissingme off because this is something that my hosting company should have taken care of a while ago.

[monkeyfun]

My hand decided to have a fight with a chunk of aluminum that got caught in a table saw. I'm bruised but not daunted. Sallying forth!

Done:
Cold weld Wire tubes to resin leg frame
Insert the video card mounting plate
Create cover pieces for the spine

In Progress:
Cut out wiring holes in main enclosure base plate
Cut Spine attachment pieces

To-Do list:
Cut the pieces for the PSU/HDD enclosure
Create frame and enclosure mounts for the PSU/HDD enclosure
Cut out switch holes on PSU/HDD enclosure
Assemble PSU/HDD enclosure
Cut the holes for the input/output ports in the back panel
Attach lightning coils to spine
Cut spine space and panels out of top cover plate
Bend and insert mesh pieces to side walls and top cover plate
Cold weld dome to cover plate
Cast resin legs
Attach legs to PSU/HDD enclosure
Create 3 part mould for shin guards
Cast resin shin guard
Attach shin guard
Cut acrylic windows for all lightning ports
Wire shin guards for LED lighting
Base paint all the parts
Paint the case
Put in all of the hardware and switches
Test run for shorts and issues
Disassemble case for transport


An actual update will be posted tomorrow or Friday.

[Snowman]

Try reloading the latest update again. I keep forgetting that some people might have difficulties if the picture urls don't have the www. listed. It's pissingme off because this is something that my hosting company should have taken care of a while ago.

ntohing but white space or broken image icons, i will try a different browser. They load fine in firefox but not in chrome... chrome is really starting to upset me with their funky image rendering.

[Fuganater]

Pics work in IE, Chrome and FF for me and I'm in freaking Africa...

[Snowman]

Pics work in IE, Chrome and FF for me and I'm in freaking Africa...

I get squat in chrome, I cleared the data two days ago and cleared the cache again today and still nothing :?

[monkeyfun]

ntohing but white space or broken image icons, i will try a different browser. They load fine in firefox but not in chrome... chrome is really starting to upset me with their funky image rendering.

Dooh that sucks, especially since Firefox has been horrible since their latest updates. You might want to check the Content Settings in Chrome (Options, Under the hood, Content settings) and see waht the Images is set to and if there's any exceptions with the Block behavior.

[monkeyfun]

Update #24: The Last Week before PAX.
Count Down: Only 7 more days until PAX 2011 (http://prime.paxsite.com/).

This update isn’t as beef as my other updates but I’m spending the better part of my days (free time outside of work) filing. I’m currently in the middle of casting one of the resin legs and I’m a bit worried. It isn’t hardening as much as fast as I like. I know it heat activated and I started the process last evening but if it takes this long I might have to create some other place holders for my legs. There is a chance I didn’t use enough catalyst. I am hopeful that I did use enough as my off-pour is setting quite nicely. Any rate, here are the resin-casting pictures to date:

First I cold-welded the wiring tubes to the frames.
http://teafromanemptycup.com/casemods/stormstrider/update24/resin01.jpg

Next I made sure the moulds were level for even pours.
http://teafromanemptycup.com/casemods/stormstrider/update24/resin02.jpg

Then I coated my moulds with Vaseline to prevent any sticking.
http://teafromanemptycup.com/casemods/stormstrider/update24/resin03.jpg

Finally, I poured the resin… and now I’m waiting.
http://teafromanemptycup.com/casemods/stormstrider/update24/resin04.jpg

On the other parts, I’m almost finished with the top covers. While these pictures are still unfinished, I’ve cleaned up all of the panel holes and softened the edges.

http://teafromanemptycup.com/casemods/stormstrider/update24/cover20.jpg

http://teafromanemptycup.com/casemods/stormstrider/update24/cover21.jpg

And I’ve prepared the mesh to be inserted into the top cover.

http://teafromanemptycup.com/casemods/stormstrider/update24/mesh05.jpg

Here’s a quick picture of me fitting the mother board and making sure my input/output panel will be cut and placed correctly.

http://teafromanemptycup.com/casemods/stormstrider/update24/placement01.jpg

LIST TO DATE:

Done:
Cold weld Wire tubes to resin leg frame
Insert the video card mounting plate
Create cover pieces for the spine
Cut the holes for the input/output ports in the back panel
Cut spine space and panels out of top cover plate


In Progress:
Cut Spine attachment pieces
Cut out wiring holes in main enclosure base plate
Cast resin legs
Bend and insert mesh pieces to side walls and top cover plate


To-Do list:
Cut the pieces for the PSU/HDD enclosure
Create frame and enclosure mounts for the PSU/HDD enclosure
Cut out switch holes on PSU/HDD enclosure
Assemble PSU/HDD enclosure
Attach lightning coils to spine
Cold weld dome to cover plate
Attach legs to PSU/HDD enclosure
Create 3 part mould for shin guards
Cast resin shin guard
Attach shin guard
Cut acrylic windows for all lightning ports
Wire shin guards for LED lighting
Base paint all the parts
Paint the case
Put in all of the hardware and switches
Test run for shorts and issues
Disassemble case for transport



Another update should be up this weekend. Anthony from Green Fairy Studios (http://greenfairystudios.wordpress.com/) is coming over to my place on Saturday to help with the priming and painting of the parts. I have to jam tonight to get more pieces ready. Do me a favor and take a look at his site and work. He’s won awards for the quality of his miniature painting and I look forward to seeing what he’s going to do with a giant miniature.

http://greenfairystudios.files.wordpress.com/2011/07/gfstudios_300w.jpg

[monkeyfun]

Update #25: Midnight Update.
Count Down: Only 6.5 more days until PAX 2011 (http://prime.paxsite.com/).

This is just a quick update in the middle of the night.

The resin casting is coming along. Here's the first half of one leg.

http://teafromanemptycup.com/casemods/stormstrider/update25/resinleg01.jpg

Here's a picture of hte top plate of the spine.
http://teafromanemptycup.com/casemods/stormstrider/update25/spine10.jpg

First lightning coil attached:
http://teafromanemptycup.com/casemods/stormstrider/update25/spine11.jpg

Second lightning coil attached:
http://teafromanemptycup.com/casemods/stormstrider/update25/spine12.jpg

All coils attached:
http://teafromanemptycup.com/casemods/stormstrider/update25/spine13.jpg
http://teafromanemptycup.com/casemods/stormstrider/update25/spine14.jpg

LIST TO DATE:

Done:
Cold weld Wire tubes to resin leg frame
Insert the video card mounting plate
Create cover pieces for the spine
Cut the holes for the input/output ports in the back panel
Cut spine space and panels out of top cover plate
Cut Spine attachment pieces
Attach lightning coils to spine

In Progress:
Cut out wiring holes in main enclosure base plate
Cast resin legs
Bend and insert mesh pieces to side walls and top cover plate
Cold weld dome to cover plate

To-Do list:
Cut the pieces for the PSU/HDD enclosure
Create frame and enclosure mounts for the PSU/HDD enclosure
Cut out switch holes on PSU/HDD enclosure
Assemble PSU/HDD enclosure

Attach legs to PSU/HDD enclosure
Create 3 part mould for shin guards
Cast resin shin guard
Attach shin guard
Cut acrylic windows for all lightning ports
Wire shin guards for LED lighting
Base paint all the parts
Paint the case
Put in all of the hardware and switches
Test run for shorts and issues
Disassemble case for transport

[monkeyfun]

Sorry for the plain picture-less update. I've been sparse with my pictures and concentrating on the case. I will have a picture progress update on Monday morning. But for now, here's the list so far...

LIST TO DATE:

Done:
Cold weld Wire tubes to resin leg frame
Insert the video card mounting plate
Create cover pieces for the spine
Cut the holes for the input/output ports in the back panel
Cut spine space and panels out of top cover plate
Cut Spine attachment pieces
Attach lightning coils to spine
Cast resin legs
Cut the pieces for the PSU/HDD enclosure
Create frame and enclosure mounts for the PSU/HDD enclosure

In Progress:
Cut out wiring holes in main enclosure base plate
Assemble PSU/HDD enclosure
Cut an dcold weold mesh pieces to side walls and top cover plate
Cold weld dome to cover plate
Cut out switch holes on PSU/HDD enclosure
Attach legs to PSU/HDD enclosure
Base paint all the parts

To-Do list:
Create 3 part mould for shin guards
Cast resin shin guard
Attach shin guard
Cut acrylic windows for all lightning ports
Wire shin guards for LED lighting
Paint the case
Put in all of the hardware and switches
Test run for shorts and issues
Disassemble case for transport

[monkeyfun]

Update #26: The Days Grow Short.
Count Down: Less than 4 days until PAX 2011 (http://prime.paxsite.com/).

Faster, faster, faster, FASTER, FASTER! Things are coming along quite well! If Tuesday or Wednesday are just as sunny as this weekend was I should have all of the shin guards cast in time for PAX. Once again I apologize for the sparseness of these pictures but I’m in a production-mode and that means my documentation will suffer.

Here’s a picture of two of the legs after the casting! All four turned out well and are useable. I should be attaching them to the enclosure tonight.

http://teafromanemptycup.com/casemods/stormstrider/update26/legsdone.jpg

Here’s a picture of Anthony from Green Fairy Studios. HE does great work but… I must admit I was a little disappointed. He is neither Green nor very spritely or fairy-like.

http://teafromanemptycup.com/casemods/stormstrider/update26/greenfairyanthony.jpg

Here a brief sample of what he’s done so far. I have to admit. I’m holding back a couple of the pictures. But trust me, the dome is looking awesome.

http://teafromanemptycup.com/casemods/stormstrider/update26/enclosureinblue.jpg

Next is the shin guard mould-making process. This mould will be a three part mould and I am cheating. There are great books and method for how to do this and ensure that your mould and therefore making the casting is an easy and flawless practice. But I don’t have time for any of these formalities.

I made a box whose dimensions are appropriate (at least 1.5” away from any part of the model) for the piece we will be making. I used foam pieces to prop the model up and away from the edge/bottom of the box. These props will fully sit inside one of the three mould parts. I coated both the box and the model with Vaseline.

http://teafromanemptycup.com/casemods/stormstrider/update26/cheating01.jpg

Don’t forget to coat the top of the box. After everything is coated, fill the box with expanding foam or gap-filler. Then wait for the foam to harden. The foam won’t stick to anything that is coated with Vaseline.

http://teafromanemptycup.com/casemods/stormstrider/update26/cheating02.jpg

More pictures of this process will probably go up tomorrow morning.



LIST TO DATE:

In Progress:
Cut Spine attachment pieces
Cut out wiring holes in main enclosure base plate
Bend and insert mesh pieces to side walls and top cover plate
Cut out switch holes on PSU/HDD enclosure
Assemble PSU/HDD enclosure
Cold weld dome to cover plate
Attach legs to PSU/HDD enclosure
Base paint all the parts
Paint the case
Create 3 part mould for shin guards


To-Do list:
Cast resin shin guard
Attach shin guard
Cut acrylic windows for all lightning ports
Wire shin guards for LED lighting
Put in all of the hardware and switches
Test run for shorts and issues
Disassemble case for transport


Done:
Cold weld Wire tubes to resin leg frame
Insert the video card mounting plate
Create cover pieces for the spine
Cut the holes for the input/output ports in the back panel
Cut spine space and panels out of top cover plate
Cast resin legs
Cut the pieces for the PSU/HDD enclosure
Create frame and enclosure mounts for the PSU/HDD enclosure
Attach lightning coils to spine

[Fuganater]

Looking great bud. I thought you said a few posts back that you were not going to PAX?

Either way, if you have to stop updates to finish up then do so. Just remember to take the pics.

[monkeyfun]

Looking great bud. I thought you said a few posts back that you were not going to PAX?

Either way, if you have to stop updates to finish up then do so. Just remember to take the pics.

Oh! I AM going to PAX, it's just a matter of how far I will get on completing this case for PAX. (I can update and comment while I'm at work. shhh...) From what I have done now, I'll have something to show it just might not be completely finished and painted.

[Twigsoffury]

Oh! I AM going to PAX, it's just a matter of how far I will get on completing this case for PAX. (I can update and comment while I'm at work. shhh...) From what I have done now, I'll have something to show it just might not be completely finished and painted.


You must focus your chi powers.

[mDust]

At the rate you're running you'll have this 99% done in a couple of days. You might just have to wait a bit for your artist to do his thing...
Everything looks great so far! Keep on truckin' like you are.

[monkeyfun]

You must focus your chi powers.

Focusing!


At the rate you're running you'll have this 99% done in a couple of days. You might just have to wait a bit for your artist to do his thing...
Everything looks great so far! Keep on truckin' like you are.

Thanks!


------------------------------------------------------


LIST TO DATE:

In Progress:
Bend and insert mesh pieces to side walls and top cover plate (almost done, drying)
Cut out switch holes on PSU/HDD enclosure (must finish filing first)
Assemble PSU/HDD enclosure (must finish filing first)
Cold weld dome to cover plate (waiting on mesh to dry first)
Attach legs to PSU/HDD enclosure (dependent on psu/hdd enclosure)
Base paint all the parts
Paint the case
Create 3 part mould for shin guards (waiting for plaster to dry, on 1 of 3)
Test run for shorts and issues (hardware tested and all parts run in another case)

To-Do list:
Cast resin shin guard
Attach shin guard
Cut acrylic windows for all lightning ports (can wait until after PAX)
Wire shin guards for LED lighting
Put in all of the hardware and switches
Disassemble case for transport


Done:
Cold weld Wire tubes to resin leg frame
Insert the video card mounting plate
Create cover pieces for the spine
Cut the holes for the input/output ports in the back panel
Cut spine space and panels out of top cover plate
Cast resin legs
Cut the pieces for the PSU/HDD enclosure
Create frame and enclosure mounts for the PSU/HDD enclosure
Attach lightning coils to spine
Cut Spine attachment pieces
Cut out wiring holes in main enclosure base plate

[monkeyfun]

Update #27: 2 Days.
Count Down: I only have Today and tomorrow to work on the case: PAX 2011 (http://prime.paxsite.com/).

I’m getting excited. PAX is always a wonderful event that I suggest everyone experience. The sheer amount of activities that happen both in and outside the event is staggering. I think I’ve been invited to 4 different vendor parties on Saturday and 2 on Friday. My schedule is booked solid with panels I want to see and new games I want to try out.

First, I donned my gear. While Privateer Press didn’t provide this bandana in their care package, I’ve earn several of them from playing Warmachine games in their Iron Arena. Privateer Press will be having an Iron Arena at PAX as well! I love getting prizes and schwag at conventions for playing games I love!

http://teafromanemptycup.com/casemods/stormstrider/update27/pose01.jpg

Here’s a quick picture of me attaching the mesh to one of the side walls. As you can see, I am a fan of paperclip and paperweight as modding tools.

http://teafromanemptycup.com/casemods/stormstrider/update27/paperclips01.jpg

Now, I’ll continue with the 3-part mould creation process for modders in a rush or the ‘How-to-cheat-in-the-mould-making-process’. Please note, a cast pieces is only as good as mould it comes from. If you put the time and the effort into making a good mould, your cast piece will show that diligence. Every shortcut you take in the mould making process will probably equal time you’ll need to spend on retouching the cast object as well.

Ok, last update I covered setting your object up in the box. Well, here’s what it looks like filled with gap-filler foam.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould50.jpg

Be sure to keep an eye on your box. The gap-filler foam expands and you should probably clean up the excess foam before it hardens somewhere you don’t want it. Here’s the hardened foam.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould51.jpg

This is the foam after the ‘unboxing’. Be sure to save that box as you’ll end up needing it later.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould52.jpg

Now I’m deciding and where to make my mould parts. You should already have a general idea of where those parts are going to be. Determining the parts is dependent on the shape of the object you are trying to replicate. The purpose of using a 3-part mould is keeping the mould parts from latching onto a recessed space on the object and preventing your from releasing the parts of the mould and retrieving the cast pieces. So you have to look at the object and determine what will be best for your project.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould53.jpg

I’ve cut out the space for the first section.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould54.jpg

Now you put the foam back into the box and cover it with a thin layer of petroleum jelly. If you’ve been using the correct amount of petroleum jelly in your project the store clerk should be eyeing you like some twisted pervert. Or you can just go to different stores or buy it in bulk.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould55.jpg

Fill the empty space with plaster.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould56.jpg

After the plaster has hardened, unbox the pieces.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould57.jpg

Cut out the second piece. Place the foam and the first piece back in the box. Cover the pieces in petroleum jelly and then fill the empty space with plaster again.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould58.jpg

This should produce two of your three pieces. The third is always a little tricky but it is done with the same process. Things you want to look out for:

Recessions made by the 2 previous pieces
Flaws in the mould
Aliens

I’m not too sure what to do if you find an alien but the other two problems can be ‘fixed’ with an excessive amount of petroleum jelly.

Please note, I am leaving some of the foam in the last piece. I’m doing this to make the cast piece a little smoother and thicker and to reduce the amount of grabbing the plaster piece will do with the cast resin.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould59.jpg

Here’s a picture of the last setup in the box. You can see all that petroleum jelly. This will cause some errant sprues on the cast resin piece, but I’m already figuring I’m going to spend a decent amount of time cleaning up the part anyhow. Once you’re ready, fill this last section up with plaster.

http://teafromanemptycup.com/casemods/stormstrider/update27/mould60.jpg

I’ve also found that there is a ‘golden’ time for pulling your model object from a plaster mould. You obviously want to wait until the plaster has solidified however you don’t want to wait too long. The longer you wait the more your plaster will crack when stress is applied to it. I usually try to extract the object while the plaster is still warm (it generates heats as it solidifies). If there are parts that are bonding or recessed behind the object you want them to break loose but you don’t want to destroy the rest of the mould.

I’ll post pictures of the final mould probably between tonight and tomorrow night.

Here’s a quick picture of the legs. I’m still cleaning them up but they will be ready to be primed later today:

http://teafromanemptycup.com/casemods/stormstrider/update27/parts03.jpg

Here are some teaser pictures of the semi-finished case!

http://teafromanemptycup.com/casemods/stormstrider/update27/parts01.jpg
http://teafromanemptycup.com/casemods/stormstrider/update27/parts02.jpg



I’ve come to terms that I’ll probably be showing a Work-In-Progress in the BYOC, but it’s put together enough that I will be proud of my work and driven to make it even better. That being said, I will probably put in another 30 or so hours of work into the case before opening morning at PAX. And once again, I will be working on this project more after PAX. I’ve talked to Anthony over at Green Fairy Studios and we’re going to rework the paint job after the convention so that it looks great for its photo session for the No Quarter magazine.


LIST TO DATE:

In Progress:
Cut out switch holes on PSU/HDD enclosure
Assemble PSU/HDD enclosure
Cold weld dome to cover plate
Attach legs to PSU/HDD enclosure
Base paint all the parts
Paint the case


To-Do list:
Cast resin shin guard
Attach shin guard
Cut acrylic windows for all lightning ports
Wire shin guards for LED lighting
Put in all of the hardware and switches
Load OS & games into HDD
Test run for shorts and issues
Disassemble case for transport

[SXRguyinMA]

it's coming along great! can't wait to see it done :D

[monkeyfun]

Still @ PAX, still MIA, will post more when I get home:
WIP @ PAX:

http://teafromanemptycup.com/casemods/stormstrider/cygnar_storm_strider.JPG

[monkeyfun]

Quick note:

I GOT 1ST PLACE IN THE PAX PRIME 2011 BYOC CASEMOD CONTEST!!!!!!!!

[msmrx57]

Congrats!!!

[Fuganater]

Gratz buddy. Well deserved.

[SXRguyinMA]

nice!!

[monkeyfun]

Sponsors:

http://www.hazardfactory.org/wp-content/themes/scratch/images/masthead.gif
http://www.hazardfactory.org/

http://privateerpress.com/sites/all/themes/privateerpress/images/privateer-logo.png
http://privateerpress.com/

http://greenfairystudios.files.wordpress.com/2011/07/gfstudios_300w.jpg
http://greenfairystudios.wordpress.com

Update #28: My PAX experience.

The event is done. The initial stress is over. And despite all of the stress, commotion, hurried frenzy and excitement, I had an immense amount of fun.

First the preparation:

Two days before PAX, I hurried to get things ‘together’ enough to present at PAX. Anthony with Green Fairy Studios gave me a fighting chance by painting most of the parts. I assembled case, wired the lights, and inserted hardware. However, my rush-job on the mould for the shin pads didn’t work out as well as I thought it would. There was a bit of a conflict with the petroleum jelly and the resin. I set the mould in the sun and heat to help catalyze the resin. The resin in turn produces heat. The heat from the sun and the resin turned the petroleum jelly into liquid. This allowed the resin to seep from the mould. :( But I didn’t let this daunt me. I threw everything together and grabbed the single shin guard and got everything ready for the morning of PAX. When I began loading everything into the car, the case slipped and both halves of the dome snapped off the main enclosure… so I did what any avid modder would do. I drilled four holes, tapped the bottom and jury rigged the dome onto the case; and it worked.

I also found that carrying 50lbs (23kg) of computer case is enough to give you a work out. I’m looking into adding rolling casters to the legs.

At the convention, I got to meet some of the best casemodders in the community (at least those in the US). Boddaker was in the EVGA booth with his TRON mod and it’s every bit as beautiful as its pictures. I was especially impressed with how he had the SSDs displayed and wired into the case. My only regret was that the case wasn’t on a turn-table so that you could easily see all sides of that beauty. BobDBone was in attendance in Zotac’s booth. He provided everyone with two treats, his casemod and the popcorn it produced. Leatherface was rocking the Thermaltake booth with two of his cases, the Scootermod and his bomb disposal robot mod(sorry if I get the names wrong on these two). The scooter-mod was particularly popular with the ladies. I can’t tell you how many times I saw a VERY cute girl posing on that scooter. Anthony Lackey had his Candy casemod in the BYOC with me. And last but not least, DarthBeavis was everywhere. No, really, had had several cases in several booths. He is a giant amongst modders and it’s always a pleasure to talk with him and get his advice on mods and the industry.

Now for the ‘thank you’ list:

My wife: Sorry guys, she gets the first and foremost thank you. She has supported me every step of the way and demonstrated patience of a saint. I love you, honey!
http://teafromanemptycup.com/alaskacouple.jpg

CPU Magazine (prize support & contest hosts): Without you and your sponsorship this contest wouldn’t be. Your magazine has great articles and features and I was happy to be participating in your event.
http://www.computerpoweruser.com/siteart/logo.jpg
www.computerpoweruser.com

ThermalTake (prize support & LAN awesomeness): Whoever is in charge of Thermaltake, you need to give Shannon a raise. This man works non-stop to help establish a community. His crowd interactions and support of the LAN made me feel as though Thermaltake was a central part of the community and that supporting this company would be like supporting a local business. Marketing reps should take note of how Shannon interacted with the people at this convention. It’s a community and we remember both the good and the bad.
http://www.thermaltakeusa.com/Images/ttLogo.jpg
http://www.thermaltakeusa.com/

CyberPower(prize support): A special shout out to Eddie with CyberPower. Not only did Eddie provide awesome prizes for the various LAN contests but he was the technical guru for all things computers. He had answered for any range of questions on tech specs, cooling, and did a bunch to find a PC solution for any type of person (from the enthusiast to the beginner). http://www.cyberpowerpc.com/

And finally LANFest by Intel (LAN support, prize support, and everything else): LANFest & Intel made the LAN possible. Plain and simple. I’m pretty sure only an entity like LANFest can make both the BYOC and the PC-Free-play areas run that smoothly. It was amazing. http://lanfest.intel.com/



Alright, now that all of that is out of the way… what’s next?

Well, I have to finish the case! I’m taking it a little easy for the next two week so that I can clean up the messes I’ve made of my basement and backyard. I’m also talking with two other foundries in regards to getting the last 7 pieces cast (3 shin guards and 4 legs). I also need to redesign the PSU enclosure (make it smaller) and re-cut the input/output panel. After all of that is done, it will be ready for Anthony (Green Fairy Studios) to re-paint the case and make it pop.

[monkeyfun]

Congrats!!!


Gratz buddy. Well deserved.


nice!!

Thanks!!! Now all I have to do is finish it! :shoed:

[monkeyfun]

Hello again! I should have another update this weekend. To tide you over check out this sweet photosynth Darkfibre put together of the case at PAX PRIME 2011! This guy has unintentionally taken pictures of my last 3 casemods in his documenting of the PAX conventions.

http://bit.ly/ntHrIW

If you look in the other galleries you can see one of my earlier ... ummmm.... attempts at a casemod? You might recognize some of the parts that I've cannibalized for future project. I apologize for the rough edges but... I was (and still am) learning. Unfortunately, I have no work log for that attempt.

http://bit.ly/po2Zyh

[monkeyfun]

Mini-Update!!!

I just got off the phone with a local foundry and they're cutting me a deal. If I show up with the moulds already made they'll only charge the me cost of the aluminum to pour it! This means I'll be doing all of the mould making and metal clean-up (cutting off sprues and down-pours) myself....

which is AWESOME!!!!!!

The shin guards will cost $12USD each and the legs about $9-10USD each for an estimate of around $80 to get all of them done!!! Considering I paid $90 for 1 gallon of resin to do 4 legs, this is an incredible deal for a quality I can control.

I am back on track again!

[xr4man]

woo hoo!

[TheMainMan]

Great to hear! You're getting some amazing support and interest on this, keep up the great work!

[monkeyfun]

The Cygnar Storm Strider casemod has been nominated for the Mod of the Month contest on bit-tech! Go to http://bit.ly/olbQFh and cast a vote (you can select more than one case to vote for)! Hopefully you vote for mine, but check out Blue Horizon it is pretty cool too!

[Fuganater]

RISE!!!!


Gonna finish this?? I really wan to see it complete!

[monkeyfun]

lol, This one IS actually still on the table. I have a surprise for it be it's going to be another couple of months before I can revive it. I have to build 2 tools to finish it.

[mDust]

I vote to finish it!

One doesn't just cast custom metal parts for a build and then scrap the project...

[monkeyfun]

I vote to finish it!

One doesn't just cast custom metal parts for a build and then scrap the project...

I agree whole-heartedly. The project isn't scrapped, simply on hold until it can be finished properly. I just need more tools (i.e. furnace, crucible, metal tongs, large pressurized propane tank) to continue. I'm also going to start experimenting with cold casting some of the parts in September/October. I might also recast some of the parts to make the case look more like the actual storm strider.