Concrete & Steel

[dooglo]

This is to be my first stab at a complete "built from scratch" mod. The topic title says it, if you haven't guessed. It will be made out of concrete.

To start with, I'm a concrete contractor currently not working because of the winter weather and economy, but I won't go there. Hehe. I got the idea about 2 or 3 years ago and did nothing about. For one, new to the mod thing, secondly, time and money, and thirdly would be faith in myself. I've followed quit a few of the guys here and on other forums around the net and have taken a lot of mental notes.

I was searching around the net to find out if someone else had tried or done one and found one over at "TBCS" forums linked here. (http://www.thebestcasescenario.com/forum/showthread.php?t=23405) I found it to be very cool for sure. I even had a double entry in posting, must of had a brain fart or something.

Anyways, the last few days I've been tinkering in my little garage building forms and etc... I have some pictures for you all to look at and please comment on.

Thanks, and enjoy.

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0213.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0213.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0215.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0216.jpg
I 45'd the corners then sanded.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0219.jpg
These are 2' by 4' 1/2" and 3/4" sheets of insulating styrofoam..



http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0220.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0221.jpg
Started lay out of block outs for i/o plate, psu, and a rear fan.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0222.jpg
Back side of mobo tray, these will be 3 windows about 2" by 14".
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0223.jpg
Top center 120 mm fan.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0224.jpg[/img
120 mm fan on top and bottom with an approximate 5" by 6" hole for optical drives and what nots.
[img]http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0225.jpg
Side panel window block out.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0226.jpg


More to come.

Thanks,

D.

[AmEv]

Three things:

One:
Bottom pic isn't there.

Two:
Ventilation?

Three:
GOOD LUCK!

[dooglo]

I'll get bottom pic fixed.

There are two 120 mm fan block outs in the front panel. 1 120 mm fan block out on top. And 1 120 mm fan block out in the rear.

I'll post more pics soon.

D.

[dooglo]

As promised, more photos, enjoy.

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0228.jpg
Side panel block outs with 1/4" ply "stuff", used for window insert.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0230.jpg
Side panel window block out with 1/4" ply stuff used for window insert.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0234.jpg
Caulking I used.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0236.jpg
Side panel block out attachment.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0240.jpg
Fan block outs.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0241.jpg
Rear i/o panel block out.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0242.jpg
All attached, front view.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0243.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0244.jpg
And the back side.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0250.jpg
Outside forms starting to be screwed together.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0251.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0253.jpg
And the top form on.
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0254.jpg
Lastly a look inside.

Thanks for looking,

D.

[AmEv]

Well,


Come to think of it...

This ain't no case someone will be stealing anytime soon.

[f8l_0e]

Have you ever worked with aerated concrete? It would really keep the weight down.

[dooglo]

@ AmEv "No kidding"

@ f8l_0e "Yes I have. Actually one ingredient is crushed lava rock to keep the weight down, plus there is another additive... liquid air"

Thanks for looking guys. Hopefully I'll be able to pour this thing and get pics up soon. One thing, the side wall thickness is 1" and the concrete will be colored just to be different. Because I can, and I have extra color lying around. Haha.

Thanks,

D.

[d_stilgar]

Looks good. I'm excited to see how it turns out.

[Fuganater]

This is going to be epic!

[monkeyfun]

nice mold making/framing. It makes me want to play with concrete....

or do something similar with a poured acrylic.

[dooglo]

Well, failure.

I'll post pics later. I guess it's all my fault. I should've known better with the mix design and re-enforcement. But, on the bright side of things, it's a lesson learned once again and I have another idea on how I'm going to get-r-done.

D.

[dooglo]

This is it.

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0261.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0260.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0258.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0259.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0257.jpg


This is it after.

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0291.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0292.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0293.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0294.jpg
http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0295.jpg



So, I'm upset. but like I said, lesson learned. Oh well.

Give me a couple of days and I'll have something else for ya. Better.


Laterz.

[AmEv]

Yes, do put some rebar in if possible.

[d_stilgar]

I assume you know what you are doing . . . so I don't want you to take any of my suggestions as being critical, but I was thinking . . .

You should consider adding some fiberglass fiber. There's a plaster of paris called Tufcal that uses fiberglass as tensile reinforcement instead of steel. I've used it in the past and it's been really good. Perhaps you could do the same thing. You could also try steel, but I know that it can be more of a hassle to reinforce that way and for a computer case I think something like fiberglass for tensile reinforcement could work really well.

I would try using less water. I'm sure you know this, but the more water you add to concrete the weaker it will be. Hydration will occur with even a very little amount of water, so I would add as little as possible and still have it workable.

Finally, it's exciting and you want to see the final result, but concrete will reach about 75% of its final strength in about 7 days. I would try to wait at least that long before pulling it out of the mold.

Good luck! We've all had our failures and it's the persistence that makes great mods.

[Wordbiker]

Very cool experiment.

To throw out a suggestion: You could embed some steel plate components into the 'crete to give yourself tappable mounting points for fans, etc. as well as some reinforcement. With the coloring it could be rusted up and would go very nicely.

[Neodymium]

Keep trying, mate...maybe next time use either fiberglass as suggested or you can use thin steel mesh as reinforcement. Good luck.

[dooglo]

Sorry for not keep you all informed on this. Since it's winter I typically do not get any work, but I just finished a re & re of a stairwell so now I can get back to this. I'll post some updates soon.

D.

[Neodymium]

Good luck! :crossed:

[dooglo]

Well, here's an update for you all. Been a while I know.

Yesterday I poured the new concrete case. This time I did each panel separately. I actually did only four sides out of the six because I wanted to lessen the weight of this beast a little and get some steel into it as well. So, I now have right and left panels as well as top and bottom. Two panels out of four have windows in them, the other two do not. But all four have some mounting holes so that this creation may be bolted together. The back side of the windowed panels have a recessed ring around the window so that the plexi will fit flush to the inside. All four panels also have wire mesh re-enforcement running through them. Currently, the concrete is curing in my garage under a concrete blanket with a small heater running to take the chill off. This go around I am not going to strip the panels out of the mold for at least one week if not more. I learned my lesson last time. I should have known better too. Oh well. So, without further ado, here are the pics I took.

Enjoy.

Pictures here show the concrete just poured and floated off.

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0327.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0328.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0329.jpg


Pictures here show concrete all finished and edged with an 1/8" radius edger.

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0330.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0331.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0332.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0333.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0334.jpg

The concrete mix that I used was a 80# bag of Sakrete found here (http://www.homedepot.com/Building-Materials-Concrete-Cement-Masonry-Mortar-Cement-Concrete-Mix/SAKRETE/h_d1/N-5yc1vZbogdZ1b0/R-100669875/h_d2/ProductDisplay?catalogId=10053&langId=-1&storeId=10051). I used the entire bag.

Each panel is 1" thick. The right and left panels are 20" by 20" and the other two panels are 10" by 20". The top and bottom panels will fit inside of the larger panels and sit on another recessed area on the top and bottom.

Thanks for looking and the interest you all have in this en devour.

D.

[d_stilgar]

Those are looking really good. Keep it up! Can't wait to see more.

[OvRiDe]

I'm anxious! I think this is going to be very cool! Good luck with the un-molding, I'll have my fingers crossed for you. :crossed:

[dooglo]

Well, short update lost of pics. Stripped the panels after ten days under a concrete blanket with a heater.


http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0351-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0352-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0353-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0354-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0356-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0357-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0358-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0359-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0360-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0361-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0362-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0364-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0365-1.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0367.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0366.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0369.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0368.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0371.jpg

http://i128.photobucket.com/albums/p177/medo69/CroncretenSteel/Photo0370.jpg

So, as you can see I've been a little busy. Now I have to shape the angle brackets, make up my mobo tray holder, psu mounting, HD mounting, and DVD/CD mounting. I have contemplated on turning this monster into a water cooled beast. Will have to see.

Thanks,

D.

[Aldersan]

Now that's a nice looking hunk of cement!

[Fuganater]

Good job! You should WC it.

[dooglo]

Well, it's a busted. During our move to a larger home, this monstrosity got damaged pretty good. I'll be scrapping this one and starting something new soon. Hopefully.

Thanks for the comments everyone.

D.

[thorkon]

Oh man, that sucks! :(

[d_stilgar]

It's a real bummer it broke. It was looking really good. Hope to see some new stuff from you soon.