Lean and Green - modular dual PC scratch build

[Waynio]

Design

Wanted a low power good capacity HTPC & looked at the range of available ones at retail that could hold what I want it to but thought I want something worthy enough to replace Stealthlow with so wanted to make it a dual system to use a lot less electric when I don't need the extra power of a normal system which is most of the time, I didn't think I'd manage making an ok looking dual system where they can still be used as completely separate rigs but I think I got there in the end & went much further, it does look top heavy but I have it figured out nicely & it will be very Heavy Bottom not the other way around ;) & I still haven't designed the case feet, want to have a good idea of it's weight before I do those.

I added a porthole window where the psu cables come out from for giggles in an otherwise super neat system internally with interesting exterior from any angle & this dual system is also highly functional, everything is easily removable & the gaming rig can be removed & placed on alternative feet & the top of the HTPC can be replaced with a plain top or test bench rig very quickly, I know this design rocks for my PC wants with it being very modular :D but as always with my designs if anything lets it down it will be the style not appealing to many but it will brighten up my eyes each day if I manage to make it as good as I hope to :D.

I took another good final examination of the design before marking the materials & tweaked it a little more to perfect it & so it will support slightly higher mobo standoffs & give it a little more strength & a little extra on the looks.

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-01.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-02.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-03.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-04.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-05.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-06.jpg



Name
Lean & Green - Yes I would have chosen a better name for it but my mind goes nicely blank caught up in the detail when I look at the concept & only random words find their way out so I'm quite happy it has that effect on me where it leaves me kind of speechless, I considered the name of Heavy Bottom because of people saying it looks top heavy but gave it a miss lol :D.



Why
Needed another reason to do a good personal build & the how much does your rig cost to run blog on bit-tech caught my curiosity to go find out & it came to about £210 for the rig alone each year, I figured I could trim that down to about £60 per year with a better use of electric separating low performance needs to high performance wants & still be able to have a performance rig to enjoy when I want so totally managed to convince myself this was a good idea so got on with it :).



System components

HTPC
ATX PSU, mini-ITX on board CPU/GPU 18w motherboard with hdmi & DVI, good low profile sound card, 4 HDD, 1 SSD, 1 full size optical, full size 140mm custom fan.

Gaming rig
ATX PSU, Full ATX motherboard, moderately overclocked quad core, 8GB RAM, high performance & quiet air cooler, 3 custom fans, good GPU, good sound card, full size optical, 1 ssd, 1 hdd.

Control of the systems, good quality cable splitters.



Materials

Aluminium 0.5, 1, 2, 3, 4, 5, 8, 10mm sheet/plate & some bars round ones, square ones & angled ones. Screws & precision DIY fittings :).
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-07.jpghttp://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-08.jpghttp://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-09.jpg

Acrylic 3 & 5mm sheets, Black, Opal frosted, Brown tint. tensol 12 adhesive.

Wood 3 types, Cocobolo, Ebony & Maple. gorilla glue bought the wood as turning blanks & they come coated in wax.


Manual modding is my approach of choice still & no plans on changing after grinding through the difficult barely skilled wondering if I can make anything phase up to feeling pretty confident about my increasing skills phase but I'm always learning & know I always will be which is probably a big part of why I enjoy it so much & feeding the difficulty a few notches higher each time in some way is making me get pretty good at this :).


Reason I am a week late on starting the thread is I've been waiting for deliveries & the last of them came today nearly 2 weeks after ordering them :D scroll saw blades, drill bits & a quality dormer tapping set so as long as I don't screw up anything I should be able to go at it until it's done but what are the chances of me getting through all this without screwing up, place your bets now :D.

First slice of progress, minimal but it's enough progress to warrant for the new thread :D.

Tackled the 3mm sheets first with them being the hardest to manage being so massive, really should have ordered smaller easier to manage sheets, d'oh, the small work bench is waaaaaay too small for the 1650x1000 sheet & the kitchen work top I used to use I found my dad made it into a fixed side table for the garage so had to improvise, quick look around & seen a bunch of beer packs :D used 5 or 6 12 packs of beer :D they made for an awesome make shift cutting table in fact they worked better than the work bench because of the even load of the packs spread out in the right places :D but it put a good bit of strain on the back from leaning over a lot & about an hour later of a jigsaw frenzy session they are to rough size within a 3mm safety measure ready for detailing, but when I marked the cut lines I forgot to make notes of which pieces are which so need to work that one out lol, should be easy enough & I'll cut up all the other sheets next, it's interesting how much I can do in a short time when going at it with a solid determined plan, I think the days of standing around for hours thinking what next? might be behind me :D.

Needed a map to get good use of the material cutting layout.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-10.jpg

Nearly as tall as me.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-11.jpg

After the 1 hour jigsaw frenzy, all the 3mm alu cut to rough size within a 3mm safety gap.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-12.jpg

Shot of the wood ready & waiting to be worked.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-13.jpg

I didn't take my ok camera to the garage though, it's too cold & would be bad for it & it was a quick get in there & get it done type task :D not faff about with a camera in the cold :) & was only me using a beer table lol which yeah I suppose would have made a good fun opening work shot really now I think of it sat in the warmth :D.

More tomorrow I hope :).

And it's awesome to be at it again :banana:.




-------------
23rd May 2012
Changes :D

The design has been a work in progress all along but I thought the first update would have been the final look of this, it's a big relatively complex design so it needed quite a bit more effort going into it so it would turn out as I want it to look & to function, I also chickened out of the wood work for fear of it being a big hassle with my tools & lack of experience of working wood & as you can see they are square 2 inch thick blocks of wood which I'd have to make slithers of to form panels so not exactly something for a wood work newb. :D

Here is how the design looks now with a side by side comparison. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-374.jpghttp://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-375.jpg

[Waynio]

reserved for final pictures :D

[SXRguyinMA]

+sub :D

[Waynio]

^ Cheers mate :D.

Since first update of cutting all the 3mm sheet to size I have been busy, marked & cut the 1mm & 2mm sheet to size & made layouts ready for printing & sticking, worked out a good way to span big designs over multiple pages accurately when using an a-4 printer.

I print & stuck the 10mm plate designs for the HTPC which just about fit on an a-4 sheet :D & drilled the holes for scroll saw access & I believe I'm tackling the toughest part of the project as the first bit lol, not because of complexity but because of tough material, good grade 10mm alu is very flipping tough :D, my small 18TPI blades cut it well but takes ages & will be great for curve cuts so since I was cutting the outer edges of the HTPC sides & front first which are straight I put the cut up band saw blades to the job but still took countless hours, was up good & early & about 5pm called it a day after getting those pieces ready for the next phase of cutting the holes out.

The bigger stand sides I will do 1 at a time trying to get 1 done each day rather than be an idiot trying to do them both in 1 day lol & that is being optimistic, I will amaze myself if I get the holes cut out of the HTPC 10mm panels in 1 day tomorrow lol I said the scroll saw is like a manual laser cutter but boy oh boy it's a slow one for chunkier materials lol.

Pictures of the day.

All the sheet alu ready & waiting for detail & the sign of 10mm plate, need glue spray to get things done quicker & better so will get some on Wednesday.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-14.jpg

10mm HTPC side panels & front panel printed & stuck.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-15.jpg

The blades & drill bits which held the start off for a week.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-16.jpg

Starting off with normal scroll saw blades at 18 TPI for thicker materials.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-17.jpg

Switched over to the band saw blades for doing quicker straight cuts.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-18.jpg

Each & every line I had to cut took a while & took a lot of concentration.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-19.jpg
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-20.jpg
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http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-22.jpg

Sneaky peeky at the chop saw in the background & the thinnest slither I took off the 10mm plate :D.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-23.jpg

My view all day today lol:D.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-24.jpg

More soon :).

[Aldersan]

Looking good!

[Waynio]

Looking good!

Thanks mate :), I wanted to do more than just cut around the outside edges but it took agaes to do :D.

[Waynio]

The lighting in the cellar was pretty bad, too dim so took the daylight bulb from my room & used 1 of my clip on light fixings so no more cast shadows in way of the cutting line & far better lighting for good work & better photos but my eye focus is carry on wandering off with it taking so long so have to stop every few minutes to regain it, taken over an hour to get the cut this far, could really do with some kind of magnifying aid, it cuts so slow you sometimes think it isn't cutting even though it is but agonisingly slow, I hate cutting thick tough material it's easily the biggest test on my patience I ever had & this is the smallest piece to be done, ugh lol :D think I'll mark every couple of mm so I can tell it is cutting :D.

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-25.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-26.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-27.jpg

[Waynio]

If I did this on my first scroll saw coffee would be everywhere from vibrations :D.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-28.jpg

Half way point of the curve cut.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-29.jpg

Lol after getting to half way around the curve cut I decided it's really going way too slow for my liking & would have taken a really long time to do the way I was doing so gambled the lifespan of the blades but carefully :D.

Glad I did, I found by pushing them close to snapping point but a little bit away from that I was getting though it pretty well indeed, took quite a few hours to realise this though so I think I shouldn't have a problem getting the 2 bigger side panels done tomorrow :).

And any straight cuts in thick materials I'll stick to using the cut up band saw blades, much quicker.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-30.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-31.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-32.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-33.jpg

Also I must have been rusty or struggling with the never tried before thickness of alu on the scroll saw when doing the first cuts so ideally I should buy a little more 10mm plate so I can remake this piece but having said that I could mod the design a touch to hide the tiny mistake & hiding it would allow for a touch more detail which isn't a bad thing so think I'll do that with it being a faint cosmetic flaw rather than a structural flaw so the game plan has already changed a tiny bit but thought of something which will just make it more detailed :D.

[Waynio]

Going at the slow pace I was before figuring how to do it faster it would have taken a week of many hours a day to get through all the 10mm alu :alien: but with knowing how to go faster now I'd say a couple of days instead :) still a long time but not bad really :D.

Also found it does the thick stuff best on slowest speed.

Got some adhesive spray & more masking tape so good to go but I think if I started right now I'd end up doing it until it's done which would probably be in the early hours so I'll pass until tomorrow so I can maintain a proper sleep pattern & put a good solid day into it :D.

[Waynio]

Started a bit late but because of skipping yesterday I just wouldn't stop until I got 1 of them done. :)

Tried the 12 TPI & they cut really well but only for about 2 inches & then they get pretty blunt & struggle to cut more so I'll stick to the 18 TPI, seem to get a whole lot more done with those on the 10mm alu.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-34.jpg

Snap, this happens more than I like but not too often. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-35.jpg

Continue
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-36.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-37.jpg

Neeeeeed fuel :D awesome pasta pesto 10 minute quick fix of goodness with a good kick of scorching chillies. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-38.jpg

Woo hoooooo feeling 50 times better so time to get this panel finished. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-39.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-40.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-41.jpg

:D More soon :banana:

[Neodymium]

Looking good, mate :D

[Waynio]

Looking good, mate :D

Thanks Neodymium :) I attempted for part 3 of 5 today of the 10mm stuff but my patience has gone walkies with the fretsaw blades lol :D so I'm going to mod a couple of the band saw blades so they can cut curves better, they eat though the 10mm alu nicely :D so should get quite a bit done tomorrow. :up:

[Waynio]

Figured it would only take a couple of minutes to mod a band saw blade by grinding it so went & done it & tested it & it works awesome. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-42.jpg

Took a few seconds to get from the start hole to be just inside the line for the cutting & can easily do the curves I need it to while eating though it nicely. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-43.jpg

And since I'm not 100% happy with the front chunky piece for the HTPC because of a tiny error while getting used to the 10mm alu I will continue to do the whole project & make notes of any bits I botch so I can make another order to re do any bad parts so it all stays to plan.

I looked on ebay for 10mm alu plate & it is far more expensive than the place I buy from, to get a replacement piece from the shop it would be £3 on ebay it would be £21 for double what I need so if I wait until I have all panels & bars ready to fix together then I won't waste money on postage unnecessarily. :)

[Neodymium]

Modding a modding tool? Nice :D

[Waynio]

Modding a modding tool? Nice :D
So glad I tried it. :D

Soooooo much better than days getting nowhere, took about 2 hours to do this whole panel & to be honest it's done better than the other. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-44.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-45.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-46.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-47.jpg

Next up is the bigger plates shown here. :D

[Fuganater]

OMG 10mm ALU!!!

[Waynio]

OMG 10mm ALU!!!

Lol :D Took some getting used to cutting it well but got there. :):up:

It had a very successful diet there :D weighs loads less now. :banana:

Just got the stand design printed & cut ready for sticking to the last of the 2 10mm plates & I'll be using the adhesive spray so should be a quick task. :)

[Aldersan]

Looking great!

[Wordbiker]

Seriously impressive work.

I've scrollsawed a fair share of materials, but 1cm alu would probably kill mine.

[Waynio]

Looking great!
Thanks Aldersan. :)


Seriously impressive work.

I've scrollsawed a fair share of materials, but 1cm alu would probably kill mine.
Thanks Wordbiker :) yeah I wasn't sure if it would do it well myself to be honest & the whole project could have been a no go :D but took the risk, if I'd have stayed with the thin fretsaw blades I'd be doing these 10mm pieces still a week from now I expect & would have needed a 2 week break from the boredom lol, my scroll saw wasn't doing a true perfect up & down cut out of the box so looked around for other users & they said take the motor off & spin it round a little & re fix it on, fixed it for me. :)

I measure marked in sketchup so I could fit the stands design on 4 a-4 sheets then drew aligning crosses with circles (2 for each joining edge), used layout to make a 4 page pdf, printed, then used a ruler & razor to cut where needed, then joined together as spot on as humanly possible & tacked together with a tiny piece of cello tape & tacked all pieces together & then completed any gaps that missed cello tape to aid in none tear application, then took the masked up panel & design to the garage, gave the work piece a good spray with the adhesive & stuck the design on it, ready for cutting. :)

These are 4 a-4 prints cut to size with a ruler & razor.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-48.jpg

Joined together carefully with cello tape.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-49.jpg

Stuck on the masking tape covered alu plate ready for drilling & cutting.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-50.jpg

Quite a process & botched the first one so needed to print another 4 :redface: but much easier & more precise than manual marking which takes a heck of a long time for me & the glue spray is a much better method than pritt stick. :D:up:

I did consider using a CAD printing company to upload the designs to so they could print them onto bigger sheets of paper but thought I'd give joing a-4 sheets together to learn a new trick. :D

This process is a bit time consuming with it being new to me so I'll do the cutting tomorrow & attempt to get these last 2 10mm plates done.

[Aldersan]

Even if its a new trick, you're doing a great job so far! Gunna be one heck of a mod when you're finished :D

[Waynio]

Even if its a new trick, you're doing a great job so far! Gunna be one heck of a mod when you're finished :D
Thanks Aldersan appreciated :) I got a tiny bit paranoid the size of the prints weren't correct so ran to check them & they are spot on, was worried for a moment. :facepalm::)

[Neodymium]

You got the tools and "modded" tools too :D...keep going, mate...looking forward to seeing more!

[Waynio]

You got the tools and "modded" tools too :D...keep going, mate...looking forward to seeing more!

:D Cheers Neodymium I have to say though I'm getting tired of cutting the 10mm alu now lol but not too much left to do of it. :D

Could really do with making an extension table for the front & sides although I suppose I could flip the blade the other way around & pull instead of push, might be trickier though but I'll give it a try, my arms keep going dead from holding the heavy plate while guiding it with 1 hand so need to stop every few minutes. :D

Anyway taking off the excess weight from the outside edges, hopefully I can dig deep & do all the outside edges at least today, still about 6 or 7 hours until I'll call it a day.

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-51.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-52.jpg

[Neodymium]

Whether you push or pull, make sure you wear some work gloves :D I was gonna say that last time, but with your "tool modding" if something snaps, its gonna hurt you...think safety ;) that said, your cuts are exceptional! this is going to be good when its done :up:

[jdbnsn]

Figured it would only take a couple of minutes to mod a band saw blade by grinding it so went & done it & tested it & it works awesome. :D

This is going to be off the hook! And I must say, a modder who mods his tools to mod a PC??? You are now filed under "bad-ass mutha modder" Ha! I can watching this build with great anticipation!

[Waynio]

Whether you push or pull, make sure you wear some work gloves :D I was gonna say that last time, but with your "tool modding" if something snaps, its gonna hurt you...think safety ;) that said, your cuts are exceptional! this is going to be good when its done :up:
Thanks Neodymium :) I don't think there is a need for gloves doing scroll saw work I think it's the safest tool I've ever used, I've had it were the band saw blade pops out of the holder & it just bends the blade out of shape which can be bent back into shape allowing it to be used again :D it's the really thin fretsaw blades that tend to snap but that's because of them being just less than 1mm wide & a fraction of a mm thick, the band saw blades are far stronger. ;)


This is going to be off the hook! And I must say, a modder who mods his tools to mod a PC??? You are now filed under "bad-ass mutha modder" Ha! I can watching this build with great anticipation!
:D Cheers jdbnsn. :banana:

Had a 17 hour sleep lol, this cold or whatever it is really kicked my rear for the first day, 17 hours :eek::redface::D but I'm feeling a lot better & my nose isn't dribbling like it were, just a slightly sore throat & temporary damaged sleep pattern so a quick passing cold.

Since the work I'm doing is noisy due to the table not being big enough to support bigger pieces on the front I'll use tonight to get all the designs ready for printing.

I made the extension surface piece last night, just need a base & bars or blocks of wood to make the height right & then fix it to the table which the saw is on, could have ordered a 6mm large alu sheet to replace the stock one but it costs £70 with VAT & delivery.

If I bought 2 3mm sheets it would be £55 delivery included & I know the seller sends them out fast, it's tempting because it won't require a complex mod, just add the mounting holes, cutting hole & dust holes & smooth off the holes & edges & replace the stock one, very tempted but I'll see if I can make an easy to remove one first with scraps lying around. :D

[Waynio]

Finally got the extension for the front of the scroll saw made. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-53.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-54.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-55.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-56.jpg

I'll be able to use both hands now for parts like this. :banana:

Progress resumes tomorrow, wooo hoooooo. :D

[Neodymium]

I want tools like yours...!!! Nice extension btw :up:

[Waynio]

I want tools like yours...!!! Nice extension btw :up:

:D It still requires good focus, steady hands & extreme patience to get through it though lol, cheers Neodymium. :up:

Ok since my sleep pattern is knackered once again but I was feeling highly focused I decided to just get on with it through the night but at a slow gentle pace so it didn't create noise & slowly but surely got it done. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-57.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-58.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-59.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-60.jpg

1 of the big 10mm pieces done, 1 more to go.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-61.jpg

And pulled all the templates & masking tape & protective film off the other 10mm pieces for a few group photos of 4 out of the 5 10mm alu pieces.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-62.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-63.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-64.jpg

Warning, cutting 10mm good grade alu even with a good tool like the scroll saw I have tests a persons focus & patience, zombie mode with keeping control high is required. :D

[Aldersan]

All I can say is "WOW!" Wait, that's not true, I can also say I want to see more! :D Keep it up, this is going to be amazing!

[Waynio]

All I can say is "WOW!" Wait, that's not true, I can also say I want to see more! :D Keep it up, this is going to be amazing!

:D Cheers Aldersan :up: I intend to stay up until tonight so I get my sleep fixed so nothing much stopping me from attempting to get the last of the 10mm stuff done today. :)

[Aldersan]

After the alu, what's next on your list of to-do's? :D

[d_stilgar]

Do you have to order those blades special? I can never find that stuff for my scroll saw.

[Waynio]

After the alu, what's next on your list of to-do's? :D

The plan is to do all the bits I think will be hardest first so it progressively gets easier lol, it sucks too much when you do it the other way around as your pretty knackered mentally & physically by the time you get close to the end if you not taking proper breaks & it will be nice to know it will get easier rather than harder, but I will need high mental focus when I start making everything fit together so I'll have a break to let my steam build back up for that, would be a nightmare spending all that time on pieces only for it to become a train wreck from 1 faulty drill hole. :D

After this 10mm alu I'll start work on all the custom fans, not sure how tricky they will be but think it will be a nice lighter task compared to the 10mm. :D Still unsure if I should add copper & brass into the rings for the fans could be pretty awesome but maybe too much bling looking, could end up looking like crazy royal jewels. :D

[Aldersan]

Lol, from the sound of it, almost anything would be easier than cutting that 10mm alu. As for the fans, try it out, see how it looks, take lots of pics, and post them of course! :D I loved your stealthlow, so I can't wait to see how this project turns out!

[Waynio]

Do you have to order those blades special? I can never find that stuff for my scroll saw.

I virtually never go looking at my local diy stores for most bits because they rarely have bits I need so I just order most bits online.

I noticed there are specific blades made for use on scroll saws & they look no different to fretsaw blades but the price difference is huge, for 12 listed as scroll saw blades they were like £8 but fretsaw blades are like £1.80 for the same amount & they do the job fine. :)

Someone else asked about this, making me think they only do fretsaw blades for wood in the US lol I find that really odd, anyway I mostly use Draper brand fretsaw blades for 10 TPI to 28 TPI the draper ones are stronger blades also or Faithfull brand fretsaw blades for 28 TPI to 70 something TPI these are meant for thin metals but found all cut any material nicely, I quickly gave up with trying to cut the 10mm stuff with fretsaw blades & used the band saw blade on them, got a 1/4 inch band saw blade & cut it into the same sizes as the fretsaw blades & modded a couple to allow for easier curve cuts, the band saw blade was by Draper also.

The lower the teeth per inch the thicker the material you can cut quicker with it & for the higher TPI you can do really thin material.

So look for fretsaw blades & piercing saw blades, you should find some in the US no problem I'd have thought.

[Waynio]

Lol, from the sound of it, almost anything would be easier than cutting that 10mm alu. As for the fans, try it out, see how it looks, take lots of pics, and post them of course! :D I loved your stealthlow, so I can't wait to see how this project turns out!

It's not so bad but does take a while to get through even with the band saw blades :D guess I just can't help but have a bit of a moan about it after sitting there for hours & hours & not cutting much lol, at least with the band saw blades you can see it is cutting, could hardly tell if it was cutting with the fretsaw blades. :D

Yeah, think I'll do that with the fans, :) could turn out they look completely amazing. :D

[Aldersan]

Lol they just might, you had some pretty crazy breakthroughs on stealthlow, so let's see you do it again! Anyways, best of luck, keep up the good work, and post lots of pics :D

[Waynio]

Lol they just might, you had some pretty crazy breakthroughs on stealthlow, so let's see you do it again! Anyways, best of luck, keep up the good work, and post lots of pics :D

:D Cheers Aldersan, the custom fans will have to wait until I can get some 0.5mm brass & copper sheet ordered but am keen to try the idea I have. :D

Ok Got all the 10mm alu cut but I have crap news & good news. :( :D

The crap news is the HTPC sides are 2 to 3mm too big on the size of the outside edges & inside edges so is no good for my design, I must have printed the design of an earlier revision, had about 10 revisions in my folder so mucked up good there, here is how they would have looked if I printed the right one.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-65.jpg

And this is how it looks in reality, missing the inside lips because of the size difference.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-66.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-67.jpg

I have checked all my newer prints & they all measure up spot on like the sketchup model so it was a pure muck up by me for using the wrong flipping model, d'oh.

Good news is I have ordered some more 10mm alu to re do them & the HTPC side panels made won't go to waste & I will make a tweaked version of the HTPC & sell it, but I won't be doing that one until I've completed Lean & Green.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-68.jpg

So at least I have the stands panels done spot on at least & they were much harder to do because of the size & weight of them when they were stock plate alu.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-69.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-70.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-71.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-72.jpg

Now I'm waiting for the extra 10mm alu it's time to pick what I'll do next, plan was to start off with doing all the difficult or patience testing bits first lol. :D

[Aldersan]

Well that sucks bud! At least you got the toughest parts done, and everybody makes mistakes now and then :) Best of luck on try 2, and keep at it!

[Waynio]

Well that sucks bud! At least you got the toughest parts done, and everybody makes mistakes now and then :) Best of luck on try 2, and keep at it!

I recover from disappointments pretty well especially if I can still use it for another rig :D but the type of accidents that can happen like dropping a piece that took a long time to do & it mangles, those are a bit harder to get over because it ends up on the scrap pile. :D

I sorted my project folder out so I won't go printing the wrong model again. :redface::facepalm:

I'll be back to progressing tomorrow, just had a little checkpoint break after the 10mm alu marathon. :D

[Waynio]

Preparations, wow nearly a week of prep work lol as well as waiting for other bits.

Figured I should do an update of some sort & make this as a mini tutorial project interval, :D not been slacking much at all & this bit took many many hours to do overall although I have been enjoying some more skyrim with some of the time I been waiting for extra supplies :D but mostly been preparation work.

3d concept, I keep all individual pieces as groups which keeps them as individual components so they don't become stuck together in the design that are easy to move around so I can just select 1 & edit it whenever with minimal fuss.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-73.jpg

Here is how I work out what dimensions of material I need for curve pieces, triple click a curve piece & measure each section on the outside of a curve which gives really close accuracy, would give perfect accuracy but when you get odd measurements like 1.56mm or 1.63 is says it like 1.6~mm so I add up to the closest big measurement which I note as 1.7 to be safe so I work entirely with 0.1mm difference for any pieces like that & then I can sand down the super faint difference to perfection & do the same for any cut outs like the round bars I'll be using on this piece, makes the holes a bit oval when it's laid out in 2d but should allow for the same as the model.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-74.jpg

Separating every piece including curved pieces ready for 2d printing on a-4 paper & adding 2 2mm squares with crosses inside them for every joining edge, then finalise the last save with camera parallel projection & then standard camera view as top, ready for layout.

A-4 is 297mm x 210mm but when setting things up to print I pretend it is 280mm x 190mm which prevents where it won't print on the paper so you keep all your needed lines, yes you can choose to print without borders but I think this way give best accuracy especially on a budget printer. :D I could give it a bit more than what I do but I like to keep it safe.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-75.jpg

Layout which lets you dump your sketchup model & make multi page printable pdf file templates, you don't get this part of sketchup on the free version though but if you look around you can find ways to buy a student license which is a heck of a lot cheaper than the retail version meant for commercial use. ;)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-76.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-77.jpg

Multipage pdf file ready for printing.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-78.jpg

And all the little files ready to print.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-79.jpg

Printed all of them & I have them in 2 different stacks, 1 for the gaming rig & the other for the HTPC, next stage is to cut them perfectly with a nice steel ruler & razer, tack them together perfectly measuring all the while & then using the spray glue to mount the templates to the materials ready to cut/drill, think prep work takes the longest to be honest but it should let the progress really flow fast once it's done.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-80.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-81.jpg

One of the stands side panels after cutting, I have quite a bit of spare 10mm alu from the big cut outs & 1 of the pieces I will make drilling, tapping helpers which can clamp to any panels, even edges & ends of bars so I can drill perfectly where I want to & drill perfectly straight with a manual power drill, so yep more custom tools to be made for doing this how I want it. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-82.jpg

Currently at 5 big steps forward & 3 big steps back but with a load of prep work done lol. :D

[Aldersan]

Wow, lots of work put in to this! It's gunna be great! And yeah, a lot of prep work done, but I'm sure it will pay off when you get to the difficult stuff! :D

[Waynio]

Wow, lots of work put in to this! It's gunna be great! And yeah, a lot of prep work done, but I'm sure it will pay off when you get to the difficult stuff! :D

I seemed to have gone to the same level of design work as someone who has parts made with CNC on this one but I shouldn't have much stalling from here. :D

One thing I'm a tiny bit worried about with the gaming rig is with the 10mm mobo spacer mounts I'll be using I should have 1mm space between the cpu cooler & side panel if I do go for the be quiet dark rock pro heat sink, hopefully it will be spot on or even 2mm space, either way it will be cutting it fine. :D

[Aldersan]

With all the work you've put into planning this thing, it should go just fine :D Best of luck, and keep up the hard work!

[Waynio]

With all the work you've put into planning this thing, it should go just fine :D Best of luck, and keep up the hard work!
:) Thanks Aldersan. :up:

Here is the bits I needed to cut the prints nicely.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-84.jpg

Back to the 10mm alu, turned out it was delivered next door & the courier didn't leave a note so I waited in 2 full days for nothing, annoying to say the least.

As soon as I lost a cold, my bro gave me the flu arrrrrgh lol but I wouldn't let it hold me down, figured if I stay in bed groaning or sit at my pc moaning I may as well mod on because I'll feel like crap whatever I do except making progress really appealed to me after so little lately. :D

I could have done pictures again but I already done that for these htpc pieces but in wrong size so I thought an ultra speed video of the whole cutting process which is 3 hours 38 minutes at normal speed but I reencoded it twice at 12 speed so 24 speed but doesn't add up for the 1 minute 30 seconds of fast video but whatever. :D
7iSOAOxIKr0

:banana: Ooohh I wish I could work that fast. :D
My first & only youtube vid until I get around to upgrading my camera to a 550d. :D

I only intended to do an example of how slow it cuts for 1 straight edge but thought meh I'll do a full panel, used my old kodak z950 which is why it isn't great quality.

I'll be going quiet again now until I have the other panel & the front low piece done so I can move on to the easier to cut panels. :)

[Aldersan]

Great work! Hurry up and get the other pieces done, I want more updates and pictures and ridiculously fast moving videos :D

[Waynio]

Great work! Hurry up and get the other pieces done, I want more updates and pictures and ridiculously fast moving videos :D

Lol, I'll have a go at getting the other 1 done today & maybe the front low piece also then I can take a good big sigh of relief of getting past the 10mm alu. :D

If I get it done by a reasonable time today I might even have a go at making some sandng blades to get all the edges real nice. :)

[Waynio]

LOL I just couldn't go to bed with being eager to try the sanding blade idea out since all the 10mm alu is now cut. :D

First up I tried making a simple sheet at the size of a band saw blade, it snapped as soon as I tried tightening it. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-85.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-86.jpg

This is the example piece fresh after cutting.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-87.jpg

Next I cut double wide to fold it over, this allows for it to be used even at high speed & has some flexibility to it but is still quite prone to ripping out of the holder but as shown on a bit of the front piece it does the job nicely but takes too long to get the finish I'm after, want that finish & better, no teeth marks at all & possibly a polished edge I should have tried to quad it up which should give it pretty good strength which I'll try when I go at it next.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-88.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-89.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-90.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-91.jpg

Other thoughts to do it is card in the middle of a folded piece of sand paper or if I want really stiff then something like the band saw blades but without the teeth & smoothed edges all around, 1mm aluminium might do, or 0.5mm stainless steel which I think would be the ultimate for doing this & would be reusable over & over, I do know I'd be best starting the process off at 100 grit or maybe even less to get the bulk of the teeth marks out & maybe work towards 1000 or 2000, it's getting rid of all the teeth marks that's going to be time consuming, from there it will come to a good shine very quickly. :D

Here is how the stand side panel was intended to look like with the htpc side panel & a shot of all the 10mm alu freshly cut ready for smoothing, I'll be saving getting rid of teeth marks & polishing the edges until the last step of the project but want to get prepared for how I'll do that. :up:
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-92.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-93.jpg

[Waynio]

Due to popular demand, picture progress report. :D

Started back up today after a little break to recover from man flu & lack of enthusiasm due to spending absolutely ages cutting the 10mm panels. :D

Got all the 10mm, 4mm cut & 1 of a heck of a lot of the 3mm panels done, it is getting easier but there is some high detail 3mm panels to be done & have no idea how long those might take I would do those next but I could do with getting a stronger spray adhesive to make sure it stays held down for the whole panel, soooo many cut outs to be done on them & this spray adhesive is only any good for simple panels.

Also shown here is the drill helpers, these particular ones are for drilling spot on on bars & on edges, I'll make a bigger one for big flat panels, will help make sure every single mount position is 100% perfect on edges of the 10mm panels & on any panels with a normal power drill.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-94.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-95.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-96.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-97.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-98.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-99.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-100.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-101.jpg

On to easier thickness of 3mm now, then 2mm then 1mm then adding all the drill mount points then an epic sanding session, then acrylic which cuts incredibly easy on the saw then gluing some of the acrylic parts together, then hmmmmm woooooooo hoooooooooooooooo. :D

Because I've gone to such lengths on the design it would probably be able to be mass produced also but have no plans at all for that but it is my most complete design so far.

[Aldersan]

*cracks whip* Why aren't you on the 1mm at least yet?! :D Just kidding, its looking amazing so far!

[Waynio]

*cracks whip* Why aren't you on the 1mm at least yet?! :D Just kidding, its looking amazing so far!

:D Thanks Aldersan, I'm aiming to have the cut work done by the 10th March, 2 weeks from yesterday, might have it done sooner we'll see depends on how much I go at it.

[Waynio]

It was proving to be a tad difficult searching through the 3mm alu I cut up to get the project started which I didn't label what cuts were what :facepalm: so it took an hour or 2 just to work out which are which & get them all labelled so continue I could. :D

Took me about 24 hours altogether to cut close to all the edges & cut spot on the seams for the multi page templates, just decided to get them ALL done so they are ready for sticking to the materials, will make for a lot less messing.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-102.jpg

So with the 10th March deadline I set for myself I have 12 days with 1 of them being today a partial day to cut it ALL now lol. :D

I will do updates every 2 days showing how much I'm getting through. :)

[Aldersan]

Can't wait!

[Waynio]

Can't wait!

:up:

Was a little concerned about sticking the busiest templates to the material with the weak spray adhesive but remembered I bought 50 a4 sticker sheets :D so printed all the busiest panels on them & got them cut up & taped together & did a final measure of them to make sure they are spot on & just stuck them to the alu.

I'll get busy drilling for access & cut them tomorrow but I'd be nicely surprised if I manage doing them all tomorrow but think it's doable, there is the front & back & both sides of the gamer rig & the rear htpc panel which are all the most detailed panels for the aluminium so expect updates to be rolling every 2 days from now with the first of them tomorrow evening or night. :)

[Waynio]

So I'm staying with the do the lengthiest bits first & remembering I bought some a4 sticker sheets I chose to tackle the busiest aluminium panels of the build out of the mountain of alu I have to cut up. :D

Freshly cut, taped together, stuck on & drilled ready for cutting, only about 4 holes I think needed to be 1mm holes, all the rest were 2mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-103.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-104.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-105.jpg

This is what I was hoping to do lol. :D
Took ???????? to do 1 of the gamer side panels
Took ???????? to do the gamer back.
Took ???????? to do the gamer front.
Took ???????? to do the htpc back.

But it took an hour to cut 6 of the smallest cut outs on 1 of the gamer side panels lol wow this will take quite a while but to be honest these tiny cut outs take far more effort to do than the bigger cut outs so I might still manage to complete 1 panel today & if I do I'll do another update later to complete this particular update but still aiming for an update every 2 days & these high volume cut out panels are definitely the most time consuming out of all of them besides the 10mm stuff already done. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-106.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-107.jpg

Anodised colour selection :D I'll know for sure which colours I'll want once everything is built up.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-108.jpg

Now I'll get right back into it but felt I was going at it for quite a while & not getting very far so stopped to check how long I was going to get those 6 tiny pieces out lol but it is very quiet work so I could go all day, all night & all day again which I very well might do & just take a 40 break every few hours to watch an episode of Chuck. :D

[Waynio]

Checkpoint 4AM :alien: but I'm going to treat each of the rows as checkpoints now I've got my technique good, each thickness takes some readapting to. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-109.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-110.jpg

40 min break for each checkpoint & no more picture updates until tomorrow. :)

[Outlaw]

It is tomorrow, no? lol jk.. Looks awesome so far, can't wait to see more!

[Technochicken]

That is some brilliant scroll saw work!

[Aldersan]

Great work! I shall hound you every 2 days for updates then!

[Waynio]

It is tomorrow, no? lol jk.. Looks awesome so far, can't wait to see more!
:D Cheers Outlaw, yep still every 2 days just a bit late posting this 1. :)


That is some brilliant scroll saw work!
Thank you Technochicken :):up:


Great work! I shall hound you every 2 days for updates then!
Hehe :D cheers Aldersan :up:

Not sure if I mentioned it here yet but I set a crazy deadline of 10th of March to get all of the aluminium cut & been grinding away like crazy to try & meet it. :D

Wowzers 8 days left to get all the aluminium cut ready for further stages, this is 1 ultra tight challenge. :alien::D

Update as promised although not as progressed as I hoped for. I feel a slap incoming on the 10th if I don't dig deeper. :D

Trust me I'm very aware I bit off a little bit more than I can chew with ease at the time limit I set for myself but I'm still grinding through the damn thing XD, I know that once I get past these 3mm high volume cut out pieces the rest will be nice & easy (in comparison), just these gamer sides I absolutely underestimated the effort they would take, I did consider making it less cut outs but left it & now I really know how hard I made things for myself. :)

Here is where the first side panel is at, it seems to take a day per row but with each cut out taking a while I found myself moaning quite a bit in a state of bewilderment instead of just getting on with it so that's the key to getting heaps more done (shut up, stop thinking & mod not walking away for a quick break that turns into a couple of hours lol). :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-111.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-112.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-113.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-114.jpg

:lol: Had to rotate the picture upside down to show correct orientation. :p
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-115.jpg

I'll be extremely glad I chose to work through the most endurance pushing bits first but at this moment it's flipping tough going & a true test of patience to get through. :alien::up:

The 10th sure was too tight of a deadline, simples, but a deadline is a deadline or it's a fail deadline, looks like 5 more days or less if I don't muck about on these gamer sides, then a day each for the front & back & htpc back which makes 8 days leaving no room for the rest of the 3mm easy panels & 2mm & 1mm, only way I can do it all in the deadline is if I wake up each morning & go straight at it & only pause for food & light chores not slacking off 1 bit until it's done, I feel it is doable & I shouldn't burn out neither & I'm not rushing it, just dedicated. :up:

[Aldersan]

Failure is NOT an option! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod!

Also, amazing work! That does take a lot of dedication, and its going to be amazing when you finish! Which you will finish, by the 10th! :D

[Waynio]

Failure is NOT an option! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod! Mod!

Also, amazing work! That does take a lot of dedication, and its going to be amazing when you finish! Which you will finish, by the 10th! :D

:D Thanks Aldersan, I really doubt I can meet my silly deadline without rushing & working myself into the ground so I'm dropping the deadline ;) but I'll just keep progressing each day. :)

[Aldersan]

Okay I'll accept dropping the deadline as long as we still get updates at least once every two days! :P

[Waynio]

Okay I'll accept dropping the deadline as long as we still get updates at least once every two days! :P
Deal :D:up:

Peanut M&Ms & nice coffee & the remainder of a heck of a mission. :D:banana:
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-116.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-117.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-118.jpg

Worth every minute & now I have another 1 of these to make. :eek::)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-119.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-121.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-120.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-122.jpg

:banana::alien::up:

[AmEv]

Wait, ANOTHER one???


Don't tax yourself too much! :):up:

[Aldersan]

Looks amazing! And yes, another one for the other side :P

[Waynio]

Wait, ANOTHER one???


Don't tax yourself too much! :):up:
:dead: Yep, another one :eek: but I'm not burning out, just going at it nice & relaxed & just get what I can done in each session, the nice thing is after these high volume cut out panels it just gets easier. :D:crossed:


Looks amazing! And yes, another one for the other side :P
Thanks Aldersan, like some have said I must like punishing myself lol. :facepalm::D

I'll relax for a few more minutes & then start on panel number 2 of these. :):up:

[Aldersan]

Best of luck!

[Waynio]

Best of luck!

I just need to get on with it & not moan. :D

[blueonblack]

I really doubt I can meet my silly deadline without rushing & working myself into the ground so I'm dropping the deadline ;) but I'll just keep progressing each day.

This. Progress each day and enjoy yourself. Read that again... enjoy yourself. That's what we do this for, right?


http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-120.jpg

This, sir, is beautiful. There was a lot of time involved but it's beautiful. I remember spending three hours marking and cutting away paper on a side panel for an acrylic mod and asking myself after an hour why I was doing it. When I was done I knew.

This is why. You're certainly no stranger to taking your time and detail, as evidenced by your prior work, so you know that, but I wanted to let you know that it shows here too. You have a thing with fluidity (also evidenced by your past work) that I could never tackle.

Well-deserved +rep.

[Waynio]

This. Progress each day and enjoy yourself. Read that again... enjoy yourself. That's what we do this for, right?

Absolutely blue :) I enjoy creating a lot & watching other peoples creations come together, guess I just find it hard to know when to call it a day though.

It's pretty much an old habit from when I started creating really that is dying hard where I feel when I start a particular piece I have to finish it in that session or at least make it to an ideal checkpoint & with me making my designs more complex or difficult to do with each new project they simply can't be done in 1 fell swoop with the amount of time it takes but I still have the mind-set of trying to but think I'm getting the hang of some parts can't be made in a quick time when doing it all manually. :D

I do know that if I just casually went at this it would take a really long time like years & there's nothing wrong with that I know, I've followed many projects that have spanned years & it's great to see updates on them.

I found if I take a few days off it can very easily turn to weeks & months so I tend to grind away at it as long as I'm feeling good & I have way too much free time really so it keeps me in high spirits. :)

Cheers for the nice post mate, appreciated. :)

And guess what?

Another update lol :D small one but thought of how to do the other panel quicker.

Didn't do much today so not much to show but when I was cleaning up around the saw I found some 10 TPI blades I forgotten about, 18TPI on the left, 12 TPI in the middle & 10 TPI on the right, they are far stronger than the others so can cut faster.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-123.jpg

They are very good for making quick work of the cutting but not good at very tight turns & useless at U-turns so I wasted a bit of time before I got my thinking cap on. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-124.jpg

I decided to take out the need to go from the opening hole to the sides with a curve by adding start holes close to the edges, this will allow me to do all the longer curve lines quickly with the 10 TPI blades & then go over them all with a more flexible blade to take out the ends, I expect I'll have this panel done tomorrow if I get a good session in, already taken out the most fiddly holes with 18 TPI blades.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-125.jpg

So early night, early rise & intend to get through this panel, would be quite something managing what was taking 4 solid days in a day.

But I will learn properly when to call it a day in my sessions. ;):up:

[Waynio]

Enthusiasm, energy & focus was getting scarily low so had to let it recharge plus there are a few other things that's been making me not want to spend much time in the cellar so things have been on pause the past few days.

The 10TPI blades cut fast but easily get stuck to the aluminium so not a good option risking high damage to the panel, already know using a lube makes it impossible to see the cutting lines so not an option, the extra 5 packs of 12 TPI came today so can get right back at it & change blades regular instead of rationing them out until they wouldn't cut a thing. :D

I'll only do thick high volume cut pieces on metal now & again because of the time they take but will stay dedicated to doing the ones on this project.

I am going to sand all edges to get an awesome all over look but I'll do that after fixing parts together but of course I'll have to sand any connecting edges so they are perfect before fixing them but the disc sander & sanding drums & sanding blades will make quick work of that. :)

This is an update on the status & a little eye candy of what is done so far for something good as a last post for a bit because I'm going to be getting really stuck into getting the high volume cut panels done & then I'll start updating again once I've got through them because I'll be able to do regular significant updates then, think doing updates between the time consuming panels is making it seem longer. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-126.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-127.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-128.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-129.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-130.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-131.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-132.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-133.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-134.jpg

Been having a big flood prevention job done over the past 5 weeks & the room I got sorted was soon filled with the stuff from the other room so has been like modding in a big bin so it's been pretty bad for keeping my mind in awesome mode really.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-135.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-136.jpg

But when they finish the job which should be this week I'll be able to get it straight again & I'll be sorting the room with the saw in to be an awesome little modding room moving all my tools & bits into it :D I'll eventually make it a sound proofed room also so I can mod whenever I feel like it which will be awesome since my energy levels seem to mostly peak at night time.

Plus I'm going to make a really good photo booth soon, it's something that has been way overdue for quite a while. :)

[Aldersan]

Great work so far!..BUT

That took 4 days for an update. Bad, bad, bad!

That better mean I get extra updates soon :D

Keep it up!

[Fuganater]

Time to start filing!



Great work so far!..BUT

That took 4 days for an update. Bad, bad, bad!

That better mean I get extra updates soon :D

Keep it up!

And when was your last update?? :whistler:

[Aldersan]

And when was your last update??

LOL I honestly haven't done much..I've got the side panel from TL mounted and everything, but I don't have the front one done quite yet..Maybe I'll find the time to do that today, Mass Effect 3 kind of had my brain for the past few days but I've saved the galaxy, so time to move on to other things :P Plus, I never made any promises about regular updates!

[AmEv]

And when was your last update?? :whistler:

Crap...:facepalm:

...6......

...


.....Months????

[Waynio]

Great work so far!..BUT

That took 4 days for an update. Bad, bad, bad!

That better mean I get extra updates soon :D

Keep it up!
:D Updates come when they come lol but should be able to properly dedicate now ;) the mess was getting me miserable with doing long sessions in there. :(


Time to start filing!




And when was your last update?? :whistler:
:D This why it's taking longer with cutting right up to the design lines so no need for filing, but still a need for sanding & still waiting on a couple of sanding drums I ordered, taking the company ages to get them in but the sanding stage will be after I get all the cut work done which still might take a while, with the ideas for the sanding it should be a fairly quick task. :):up:


LOL I honestly haven't done much..I've got the side panel from TL mounted and everything, but I don't have the front one done quite yet..Maybe I'll find the time to do that today, Mass Effect 3 kind of had my brain for the past few days but I've saved the galaxy, so time to move on to other things :P Plus, I never made any promises about regular updates!
Hehe, games can suck up your time like a black hole :D skyrim :eek: so many hours can just disapear playing that. :D

And sure I won't make promises about updates again unless I am totally sure. :D


Crap...:facepalm:

...6......

...


.....Months????
Ugh lol :D 2 weeks doesn't feel so bad now hehe. :banana:

The other room is done now & spent the night sorting the cellar so I can at least stand long sessions in there again.

Before :(
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-135.jpg

After :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-137.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-138.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-139.jpg

I can get on with the cutting now without feeling like I'm sat in a garbage dump, already feels a lot nicer in there so you can definitely expect regular updates to start rolling on again now but first I need a rest, just thought I'd update that it's waiting for me to spring back into action now instead of anything holding me back, think I'll continue doing all the time consuming stuff first as planned. :)

Still loads of hoarded useless junk that fills the shelves though & want to clear it all out ASAP & get some really cheap but decent kitchen worktops to go along 2 or maybe even 3 walls for all my main tools & have a nice dedicated assembly spot, then all I'll need is a load of chunky wooden beams to form them into tables :) already got a very nice piece of kitchen work top which I'll make my scroll saw table with as soon as I can with all the different blade types having their own holders because the silly long table I'm using is very prone to rattling & I'd much prefer a sturdy smaller table that I can bolt the saw to so it's nice & solid not a bit prone to rattling.

But really I think I can complete the project with the room as it is & will bring my other tools & the foldable workbench over later today & just use them on the floor for the time being, got the space now, woo hoooooo, can’t wait to really get stuck back into this. :D

I would get back to cutting right now but I am very knackered & really need a few zzzzzzzzzz lol. :D

[Aldersan]

I think you should finish this with regular updates, then make a worklog of transforming your work space :P

[Waynio]

I think you should finish this with regular updates, then make a worklog of transforming your work space :P

I agree :D:up:

[jdbnsn]

Those cuts are amazing, you are a patient and passionate creator sir!

[Waynio]

Those cuts are amazing, you are a patient and passionate creator sir!

Thanks jd :)

After sorting the room & as soon as I woke up I went at the 2nd detail panel & what an awesome idea it was to do mirrored panels of ones that take ages to do lol ugh anyway with having plenty of spare blades can change them when needed so it still takes many many hours to do but can do a lot more in a shorter time, I'd say 1 big session left to do on this.

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-140.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-141.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-142.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-143.jpg

Progress rolling forward. :)

[AmEv]

Careful bout saying "rolling forward".... :whistler:

[Waynio]

Careful bout saying "rolling forward".... :whistler:

:D True

[Waynio]

Holy moly I'm a happy chappy now this scroll saw endurance test is done. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-144.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-145.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-146.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-147.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-148.jpg

So that's 2 pieces which I expect is easily the most time consuming bits cut & ready for sanding, still got the htpc back, gaming rig front & back to do which is all 3mm alu also but these side panels are definitely the most time consuming panels.

Overkill mesh lol. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-149.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-150.jpg

Not only nice progress but a clear sky with some sweet warmth from the sun, man I've missed that. :banana:

[Aldersan]

Amazing work, and it shows! Keep it up! I wanna see this build finished! :D

[Waynio]

Amazing work, and it shows! Keep it up! I wanna see this build finished! :D
Thanks Aldersan, I'm hoping to do regular progress now & it should just keep getting easier as I go with tackling the most difficult stuff first. :D

Just acquired a load of this 2mm thick brass hex mesh stuff, more than I'll ever need lol, this is 1 tiny sheet of it & there are I think 4 much bigger sheets of it. :eek:
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-151.jpg

Also got started on the htpc back panel. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-152.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-153.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-154.jpg

:D:up:

[diluzio91]

subbed... can't believe i missed this... haha... looks good

[Waynio]

subbed... can't believe i missed this... haha... looks good

Cheers diluzio91 :)

Woke up with clear intentions to complete the htpc back panel & keep pressing on with the build.

My dad mentioned about shifting some stuff from the garage to the cellar the other day but today I overslept a bit & he decided to shift most from the garage to the cellar so instead of making things I had to just go with the flow since he made it into a sheet tip again lol so carried the kitchen unit cupboards & draws & work top over & put them along the wall, still need to remove the shelf above it else having a worktop there will be useless.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-155.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-156.jpg

So yeah I'm back to sorting the cellar out & get it all nicely functional again at this point so no progress today with having to do this.

[Waynio]

Ready for carrying on again :D but now with all my tools ready for action in the cellar & plenty of storage, workshop still needs a lot more attention but it's totally usable again for the time being & with a lot more function.

Scraps area & a load more has been added from the garage since this photo of acrylic, bars, sheet alu & copper bars & sheet, will be a perfect selection, so much good stuff to pick through & will be great for some freestyle modding. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-157.jpg

Work top area & all the tools on there can be placed inside the cupboard leaving a big blank work surface & it has mounting holes for a vice, grinder/polisher & bending brake which hasn't seen a lot of use from me to be honest because it's only any good for 1mm sheet really but it's there for whenever I need it.

Draws filled with many various types of drill bits, loads of types of nuts & bolts (I should buy a couple of small compartment storage boxes for them), adhesives, fillers, small hand tools, files & cutting bits.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-158.jpg

Cupboard shelves with some hand manual/power tools, more files, clamps & sand paper from 60 to 2000 grit in closer gaps for each grit now with room for much more stuff.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-159.jpg

My scraps need a good sorting through for what could be useful & unuseful & to sort them into same types & thicknesses nicely arranged for easy selection & all my modding bits need a hefty sort through also, have 1 huge box & about 7 smaller boxes of lighting, fans & all kinds of modding bits including retail case parts but with me now knowing how to make my own main important case pieces I have no need for them anymore so already know I can have a good clear out instead of becoming a massive hoarder. :D

Really starting to feel like a workshop & think modding will be much more fun as it should be from now. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-160.jpg

Off/on topic :confused::D.
Because of me mucking up by showing the doubled up panel in it's best lighting & some approving of it lol I couldn't hold myself back from having a quick mess about in sketchup as well as checking out different orientations of the actual panels. :D

A big part of what makes it look good doubled up in reality is the inside cuts catch reflections & cast shadows under the right light with them being 3mm thick, if I doubled these up they would mess the planned design which would be a problem so natural choice to me is stay with the design & either use 1.5mm sheets or 3 1mm sheets, but with the lack of depth might not look as good, also I got the feeling wood wouldn't fit in with it all so if I did go that route I'd make it all out of aluminium, colours used in this example are titanium, grey & black, kinda looks good to me but I would love to throw some nice colour into the project, this is like a black & white movie so if I did go this way I'd have to put a good colour scheme together & think the perfect colour scheme would come in the form of paints, not anodising. :D

But having said that I could smooth off the ends so instead of having a frame around them they simply smooth & blend off to the edges as a rounded bevel edge, certainly a crazy amount of work though doing 2 more of these panels & would add more weight to the top half.

As for colouring I think paint would be the best way because I can pick from an infinite range of colours & do some blending to form a real nice colour scheme, the range of colours on offer at the anodisers is very limited & know I could really broaden the range of colours if I DIY the anodising, would be a really sweet skill to gain also, would make me completely self sufficient at all my creating.

1 Thing I like about not using the wood is I'll be dealing with materials I know won't be prone to splitting/chipping/warping, never made panels from slithers of wood before but I am up for giving it a shot, this alternative look is not a sure thing yet, I just explored the option a little. ;)

I particularly like the look of it from a looking up at it angle, looks chunky & pretty badass. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-162.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-163.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-164.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-165.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-166.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-168.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-169.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-170.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-171.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-172.jpg

Intended look comparison.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-03.jpghttp://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-167.jpg

And back to the project, on the last episode.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-161.jpg

I aim to get this panel done today & know it's very doable with taking out all the tiny cut outs first, they might not take the longest to do but they require more concentration to do. :)

[Waynio]

HTPC back panel. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-173.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-174.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-175.jpg

I'll do the back gamer panel next.

[Aldersan]

Looking good! Can't wait to see all sides together!

[Fuganater]

I wish I had this much free time...

[Waynio]

Looking good! Can't wait to see all sides together!
Thanks Aldersan neither can I mate. :D


I wish I had this much free time...
Lifes tricky, either too little time but got money, waaaaaay too much free time & virtually no money. :?:facepalm:

Thinking update. :D

Slacked off yesterday :D spent a bunch of time working out what direction this is going in, I'm not mad keen on doing 3mm doubled panels but might if I can dig deep enough to do those again :D & thin panels wouldn't create the reflection or shadow thing as much but I found doing panel surfaces whatever colour I will & keep all the edges nicely sanded & raw, creates a nice effect overall.

And had a go at the feet design, 30mm high, as deep as the gaming rig & a little bit wider, combination of 10mm plate alu, 6mm rod, 3mm rod all interlocked together. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-176.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-177.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-178.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-179.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-180.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-181.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-182.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-183.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-184.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-185.jpg

I do believe I'll make these overkill feet. :D

[Fuganater]

Not overkill. Functional.

[AmEv]

So, when are you going to ship it to me???????

[Waynio]

Not overkill. Functional.
:) I have just toned it down a little. :D


So, when are you going to ship it to me???????
:D

Slight revision of the feet, when cheapskate says he thinks it's too crazy it really must be :D so I removed the rods, added a full length middle support & made it less wide & it all still interlocks nicely, so much so that it might not even need any bolts other than to fix to the base of the rig, this was 1 of the other neat things I was thinking of when deciding to buy the scroll saw, nicer ways of putting things together, not just nice detail panels. ;)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-186.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-187.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-188.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-189.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-190.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-191.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-192.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-193.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-194.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-195.jpg

Now to carry on with the cutting, I think that back gamer panel might take a while. :D

[Waynio]

Started with a fresh 12 pack of blades to see if I could manage doing the back gamer panel with just those.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-197.jpg

Problemo, but spotted before I mucked up beyond recovery, the bottom right cut outs in this shot don't line up with the next row, the row beyond that do though, I already done the starting drill points a while ago now but I think I can salvage it by tweaking the design just enough to let me get away with the mistake, I started trying to manually do it but it's a bit too technical to do anywhere near as good as I could if I tweak the design to fix it & then print & stick it over (still got no drawing aids), they are definitely a bit too much out of flow for my liking, wouldn't even be noticed on normal shots but on macro shots it sure would & I'd like to do a ton of photos of this once it's done so instead of completing this panel now I have to fix the design, print, stick, then continue. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-198.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-196.jpg

Here is what I got cut today though so far. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-199.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-200.jpg

[Waynio]

Error in the back gamer panel pattern that I couldn't go ahead with, some of them were out of place by as much as 3.5mm, you have to look close at it to really see it. :eek:
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-196.jpg

Fixed & added an extra cut out because there was room for 1. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-201.jpg

Off to print this fixed one & very carefully stick it over the faulty one, retained all the drill start holes in original place too, a spanner in the works nicely pulled out just in time. :D

[Waynio]

Fixed pattern applied & already working on it, this shot makes it look wonky but that's just the sticker sheet risen up a bit, it pressed back down nicely. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-202.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-203.jpg

And say hello to my little finger choppers. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-204.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-205.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-206.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-207.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-208.jpg

These will occupy the 2 main front fans & I'll be applying my custom fan frames to these but I think I'll redesign the grills I was going to use so it's a bit safer. :D

These fans come run at 1600RPM but also come with a 900 & 1200RPM cable, I'll use the 900 for the htpc, not sure about the gaming rig yet.

[Waynio]

Finished cutting the gamer back panel. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-209.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-210.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-211.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-212.jpg

Up next the gamer front panel & then a little break so I can get the scroll saw out of my dreams lol. :D

[Fuganater]

Wow... great work man.

[Stonerboy779]

Wishing you owned a water jet yet?

Great work and what colour is the plexi going to be?

[Waynio]

Wow... great work man.
Thanks Fuganater :)


Wishing you owned a water jet yet?

Great work and what colour is the plexi going to be?
Would be sweet to have access to one + know how to use it properly :D but I don't so I'll go this way, :P Just takes longer & more effort. :)

The plexi I bought is brown tint, even if I don't use the wood for this project I think it could still work well, not sure if I mentioned it here but I might switch the wood extras for aluminium, got worries about it splitting or warping & being a PITA, :D Some of the slithers I had in mind were as thin as 1mm thick. :eek::facepalm:

But when cutting the outside edges of all these panels there were many slithers I took off that must have been about 0.1mm thick, was like tin foil lol so actually cutting accurate slithers isn't my worry, it's more with the characteristics of the woods I chose.

Decided I'm going to have a little break from the project to enjoy some sunshine while we have some & catch up on a couple of the ever increasing backlog of awesome games I have :D & I could smell the detailed chunky aluminium panels coming to an end so thought the heck with it & pushed forward, I don't consider acrylic the tiniest bit difficult to cut on the scroll saw compared to aluminium, it's sanding acrylic to a sweet finish which is a nightmare lol. :D

So the last of the detailed chunky panels, gamer front, start.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-213.jpg


I'm surprised I did these super tiny holes, the 1mm drill bit I used just about fit this cut out lol, but I did the drilling well before so couldn't not do it leaving a drill hole, had to get my very fine blades out for this 1, quite proud I managed to do it nicely. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-214.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-215.jpg


This circle hmmmmm, why didn't I just drill the right size?, maybe it was because I didn't want to risk drilling badly.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-216.jpg


Done, well not done but cut at least like all the other panels so far. :p
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-217.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-218.jpg


So, with me taking a break from it to recover I thought I'd take photos of all the work done so far. :)



HTPC sides & front 10mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-219.jpg

Stand sides 10mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-220.jpg

Stand bottom 4mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-221.jpg

Gamer top pieces 3mm & 4mm, it'll make sense later in the project. ;)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-222.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-223.jpg

Gamer side panels 3mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-224.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-225.jpg

HTPC back panel 3mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-226.jpg

Gamer back panel 3mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-227.jpg

Gamer front panel 3mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-228.jpg


Group hug photos. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-229.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-230.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-231.jpg


So time to relax before I get back at it & when I do the rest of the scroll saw work should be quickly done & ready for stage 2, I’ll try to get the feet finalised in the meantime, there is still a lot of cutting to do but it's all far more simple & then it goes to the thinner material which I can breeze through. :)

Also got the sound card ordered for the HTPC, PITA how you can't buy auzentech sound cards in the UK now, had to buy direct from them, there are a few alternative shops but I wouldn't buy from them with all the bad feedback they have, went for the x-fi forte low profile card, got to have awesome sound on a HTPC. :D

At least a week before another update. :bunny::D

[jdbnsn]

Inspiring work bro, you are like tribaloverkill with your obsession for perfect cuts and I love it! You make laser cutters weep with shame...kinda reminds me of John Henry vs the railroad machine :)

[xr4man]

You make laser cutters weep with shame

hahahahaha

[Waynio]

Inspiring work bro, you are like tribaloverkill with your obsession for perfect cuts and I love it! You make laser cutters weep with shame...kinda reminds me of John Henry vs the railroad machine :)
:redface: Don't know what to say to such an awesome comment :D thanks mate. :up:


hahahahaha
:D

Bracing myself to get back onto it, had a bit of rest to catch up on. :)

Fan grill revisions since I went for the chopper fans. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-232.jpg

Second design is a further developed version to be a little safer than the originals I was going to use.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-233.jpg

Think I like this 4th one the most, looks ok & won't be restrictive & will prevent fingers being chopped not that I ever place my fingers into fan blades but some crazy might. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-234.jpg

Revised feet again, chopped the front 2 feet off & replaced with 3 stacked 10mm small panels shaped to work a bit better with the look of the design & removed the side middle feet & created a bigger arch, kept the back the same.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-235.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-236.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-237.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-238.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-239.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-240.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-241.jpg

Should be able to do the 10mm triple layer parts from scraps from earlier 10mm cuts.

I think I can make these, won't be easy but it's doable with a good accurate cutting, filing & drum sanding session, still waiting for my drum sanders BTW, well over a month & supplier not sure when to expect, they are incredibly good which is why they in such high demand, you can put whatever sandpaper you want on them, already got 1 but it's a big 75mm one, waiting for a 12.5mm & 25mm one, they make such awesome work of cleaning up edges & very fast, can use them in a power drill or drill press.

I'll continue with the actual creating in the next couple days, still loads of panels to cut but nice & simple ones. :)

[Waynio]

Settled with intended grills but with the extra guards, the feet I removed the middle layer which will make them a little easier to make & think they look better so are now happy feet lol. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-243.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-244.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-245.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-246.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-247.jpg

Flying squirrel feet. :banana::D
http://2.bp.blogspot.com/-o6AFIjUws-Y/T1kk3SnDPGI/AAAAAAAAM0I/AWJi591FD04/s1600/flying_squirrel.jpg

[Stonerboy779]

If you want a vote I would say go for something between 1 and 2 so one extra band not two.

[AmEv]

Random animal! Ack!~

[Waynio]

If you want a vote I would say go for something between 1 and 2 so one extra band not two.
I tried it I liked it :) cheers stonerboy. :up:


Random animal! Ack!~
Lol :D

Progress woooo hooooooooo, feels good. :D
Fan grills are down to these 2, I like them both really, was suggested by stonerboy on TBCS to just have 1 ring on the original design & it does look better than 2 extra rings.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-248.jpg

Got 5 Pieces done today, only spent about 3 hours though so not bad. :)
And here is the drill helper in action, makes it so anyone could easily drill precisely where they want to, it is 100% spot on where it should be, you just place it & clamp it & use the power drill with minimal effort, brilliant, just need to make a bigger one for bigger panels but they can be made rapidly. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-249.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-250.jpg

Mini-ITX mobo tray cut, drilled & countersunk ready for the 10mm female to female stand offs & m3 6mm countersunk screws, tested mounting a full ATX mobo to it & the mounts are completely spot on, I love digital callipers & printing designs. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-251.jpg

Installed
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-252.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-253.jpg

HTPC bottom level.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-254.jpg

HTPC 2nd level.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-255.jpg

HTPC 3rd level
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-256.jpg

Gamer rig bottom level with mini-ITX mobo tray.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-257.jpg

Altogether
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-258.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-259.jpg

The growing stack of parts just waiting to suddenly transform from a mess into a structure. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-260.jpg

It's always been a battle for me to keep a regular sleep pattern when getting into a project, nearly went for doing some sound isolation in the workshop so I could create any time but after weighing it up it simply cost too much to do so realised a really loud alarm clock was the answer by the name of "Sonic bomb" has really sorted me out so expect regular progress now, that thing can't fail to wake me up & I really put it to the test for this morning because I went to sleep at about 3AM & set it for 6:30 & it catapulted me out of bed, disturbs you so bad you don't bother with snooze, precisely what I needed all this time & is what has been delaying progress, being energetic at completely wrong time of day but this is fixed now, I'll just have to go easy on the coffee late in the day. :D

[Waynio]

More HTPC parts I did today.

The motherboard tray doesn't screw in place, it's held in place by a bottom, middle & upper layer & slides in/out for sweet easy maintenance, big part of the functional side of the theme, a dream for easy maintenance, something I really do like in a build. =)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-261.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-262.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-263.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-264.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-265.jpg

Few more parts for screw less fixing of parts, 2 of 4 layers for HTPC internal sides, optical holding piece, extra piece for holding the hdd cage in place, another level for the HTPC & a few small bits to form the front of the HTPC.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-266.jpg

Parts pile grows further.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-267.jpg

More tomorrow. :D

[Fuganater]

That's a pretty awesome idea!

[Waynio]

That's a pretty awesome idea!

Cheers Fug :) only the main structure fixes with screws & rods, everything else slides & slots in place, should be real nice to maintain, be excellent for dusting time also. :D

Fan grills was 5-1 for the original grill with extra ring so I'll do those.

Felt too tired to create yesterday.

Since changing some parts from wood to aluminium I'm not sure if I have enough so might need to get some alu ordered, the wood side detail pieces are meant to be 5mm thick, I have no large enough 5mm plate so might do a double layer of 3mm adding an extra pattern that compliments the main one, we seen how it gave a nice effect doubling up the 3mm panels so it makes good sense to do that in this part if I have enough material anyway.

The scraps of the 10mm plate are more than enough for the feet though, measured them. :D

I could start building things up already now to boost some extra life into the log but I won't :P I don't want the form to get old like stealthlow did, plus I want to focus on 1 aspect at a time so it suddenly rises up when it's all ready to for a big ass wow moment. ;):D

So I think today I'll do the rest of the 3mm stuff & if I'm still feeling energetic make a start on the feet which I have no idea how long they will take me, 10mm takes a while to cut well. :freakedout:

[Waynio]

Back to the land of chunk for the feet.

Templates printed on sticker paper & applied to some of the spare 10mm plate.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-268.jpg

And it begins & to be honest I find this easier than those crazy 3mm side panels, they really did feel like they were taking forever to get through.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-269.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-270.jpg

Had to take a picture of this odd creature. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-271.jpg

Fine cuts.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-272.jpg

Done 1 of 5, I started pretty late in the day & it already hit 17:30 by the time I did this 1 piece so thought I'll do the rest on a long day tomorrow with an early rise, at least I know the curve cuts are doable with the standard band saw blades & just the notches need taking out with the finer blades for easier turn cuts.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-273.jpg

Tested a piece of the 10mm alu slotted into the notch & it's a perfect tight fit. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-274.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-275.jpg

[Waynio]

40% complete feet. :) More exciting cutting. :facepalm: but it is good progress so I'll shut up. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-276.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-277.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-278.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-279.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-280.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-281.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-282.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-283.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-284.jpg

I'll try to finish these tomorrow, not much more to do & will have the first bit of filing to do on the front pieces of the feet. :)

[Waynio]

Progressed a very good bit for the feet, all I need to do now is 5 drill hoes going about 7mm into the plates ends but then I need 6mm aluminium rod, I could buy some or I could sand down the 1/4 inch rod I have, cut a few pieces & JB Weld them in place & these feet will be rock solid but I'll save the JB Weld for after anodising. ;)

Also then need to do some well placed holes for mounting the front plates & then mounting holes for attaching to the bottom panel.


Did these 2 yesterday.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-288.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-289.jpg

Completed the other 2 today so that's the set, next stage for these 4 pieces is a big filing session to get the angles how I want them.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-290.jpg

Last 2 side legs.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-291.jpg

Drill helper in action.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-292.jpg

Finishing the holes to desired depth.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-293.jpg

More cutting.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-294B.jpg

More sanding.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-295.jpg

Ta daaa, interlocked. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-296.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-297.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-298.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-299.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-300.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-301.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-302.jpg

Parts pile grows again. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-303.jpg

I'll try to complete the feet tomorrow if I can, thanks for looking. :)

[_ferry_]

This is awesome! You don't need a CNC. You ARE a CNC ;)
( don't know if ther's a CNC which tries to cut his own hand. But whatever ;) )

BTW, i only got the small saw blades for my scroll saw, like these (http://p.alejka.pl/i2/p_new/28/23/proxxon-brzeszczoty-wlosowe-ze-sworzniem-sredni-zab-prn-28-742_0_b.jpg)
The one you're using is like these (http://www.allekabels.nl/product_images/s_9705146i.jpg)? Do they work well with a scroll saw? I guess so because you're using them. But i think it's hard to make circles with them? Pretty sure they'll last langer than the thin ones.

[Waynio]

This is awesome! You don't need a CNC. You ARE a CNC ;)
( don't know if ther's a CNC which tries to cut his own hand. But whatever ;) )

BTW, i only got the small saw blades for my scroll saw, like these (http://p.alejka.pl/i2/p_new/28/23/proxxon-brzeszczoty-wlosowe-ze-sworzniem-sredni-zab-prn-28-742_0_b.jpg)
The one you're using is like these (http://www.allekabels.nl/product_images/s_9705146i.jpg)? Do they work well with a scroll saw? I guess so because you're using them. But i think it's hard to make circles with them? Pretty sure they'll last langer than the thin ones.

Hehe thanks ferry, :D I'll be taking safer measures from now on when using the scroll saw though. ;)

The first scroll saw I had would only take pin end blades like the ones you shown, I wanted one that could take plain end blades because there was more types available going up to very high teeth per inch & were cheaper, but I didn't just go for one that had that feature I went for one with a wealth of nice features, it cost a lot but I had it spare at the time so mine can take band saw blades also, all I do is buy a band saw blade & cut it into correct sized pieces so I think I got about 15 blades out of 1 band saw blade.

The thicker blades you shown are junior hacksaw blades but I don't know, maybe they could work on a pin end blade scroll saw if they are the same length, well worth checking out I say :) do you know if yours can accept plain end blades or not?.

Plus if cutting tighter curves like a fan hole normal blades are still best for that, I use the chunkier blades for slight curves & straight lines to get through it faster. ;)




Decided to start doing more actual WIP pictures but don't want thousands of pictures to upload over the course of the log so I'm starting to bunch them together either in 2s or 4s so it shows a more complete progression & showing full pictures for finished pieces or near finished, I'll put a / in-between descriptions of each picture cluster. :D

It's cool in the cellar but not like 0c or below like it was in the garage when it got colder which made me leave my camera in the house so I can keep it aside on every session now without worrying about it causing damage, even my mp3 player used to crash when over in the garage because of the cold, it's probably about 10c in the cellar virtually all year round, really nice temperature to mod in.


Back to hand tools woo hooo :D which let me use my full force, I missed it so much really, it exhausts the body which is a way I'm far more used to, whereas the scroll sawing exhausts the mind mostly with having to go at it's pace instead of my own so that tires me more than this, this just calls for regular recovery breaks & more showers because it makes me sweat a lot & it's cool in the cellar, usually need a fleece on. :)



Here they are just after carefully scoring them with scalpel & ruler so I have perfect lines that won't come unstuck while they get filed. / Templates removed showing the lines. / Harsh file, medium file & soft file. / It begins.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-304.jpg

Busy / busy / busy lol / done 1 edge. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-305.jpg

I was having difficulty clamping the small pieces on the workbench so decided to cut up to the peg holes in it so I could get them further in, the peg holes are supposed to act as a type of clamp but I never use them because they are rubbish, so no loss & all gain. :D / It worked excellent, I had to place a bit of same height scrap so I could catch the angles right.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-306.jpg

Busy / I find throwing my leg over helps to prevent back ache & lets me throw more force into it.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-307.jpg

Done the filing stage of 1 of these pieces, I started late & it was getting very late so called it a day, up next for these is a quick drum sanding session which will make them very nice. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-308.jpg

A few pictures of the result.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-309.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-310.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-311.jpg

And I have thought of how I can fix these to the legs without making it an impossible assembly which could be tomorrow if I start early enough. ;)

Next update should be less wordy too, just had some things to mention with changing the style of the log a little. :D

[Waynio]

Taking a little longer than anticipated to do the feet, what a surprise. :)

Filing / Weren't the same as each other which I expected with them being complex-ish & only doing a partial template. / Clamped them both together & filed them to be the same or at least very similar. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-312.jpg

Pretty nice I think after a few swipes of the drum sander on 240 grit.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-313.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-314.jpg

Tried doing the small pieces the same way by clamping them but they are too small to do that so I first tried to grind them down on the disc sander, didn't seem a great idea so fixed up a massive vice which was wasting away in the back yard so I could file properly, I used a little of the grinded angle as a guide for what angle I needed to file at & then finished off on the disc sander, these small pieces were far more work than the bigger triangle pieces but all parts are now ready to fix together.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-315.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-316.jpg

I then got my drum sander on the go in the drill press to make all visible edges a bit nicer, they still need more finishing but they are quite nice now, the smaller pieces mount upside down to how they are in the pictures.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-317.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-318.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-319.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-320.jpg

I'll try to complete the feet tomorrow, careful bit of drilling, cut a few rods & it should be a pretty simple process, would have done it in this session but I was feeling wasted so called it a day. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-321.jpg

Sound card came today. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-322.jpg

Found another place which had the extra drum sanders in stock, a rocking horse specialist shop :) so I cancelled with the one I been waiting about 2 months for & bought from the new place, should have them soon hopefully.

[Stonerboy779]

Not sure if i am a fan of the feet yet, will have to wait see.

[Waynio]

Not sure if i am a fan of the feet yet, will have to wait see.

Here you get to see, they do still need some fine tuning on the finishing but they are functional now. :)

At a stage where I need to be extremely careful so I don't screw up the effort to cut the pieces so I made a new drill guide to support 6.5mm bits now because that's the needed size for the 1/4 inch aluminium rod so have a load of 6.5mm & 2.5mm guides for rods & tapping holes, also the square bar I use for this is 3/8 inch thick so 0.5mm too small so I made it up with about 5 layers of masking tape on both sides. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-323.jpg

However drilling deep with a power drill is still too unpredictable with a 10mm thick guide, I'd guess maybe a 30mm guide is needed for deep straight drilling, I'll make one for further deep drilling later in the project but this went ok just about & got my rod pieces plugged in.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-324.jpg

Plugged & slotted all pieces together & was flipping perfect, I was really happy & still am. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-325.jpg

This one I have to explain in words because it was difficult & I couldn't be bothered messing with the camera, it was pickling my head & was getting late & I was wasted once again. :D

Then had to mount the underside front bevel pieces, I sat & stewed on how I should do them for quite some time & then just decided to make them join the bottom stand panel, I first placed masking tape along the line for where they should mount, drew rough lines for where not to drill, then dotted 6 marks to drill on the bottom panel, then came the tricky part, aligning it right & clamping it so I could do starter holes to finish off on the drill press into the bevel pieces, I used 2 stacks of 10mm aluminium to support the bevels & spent ages getting them aligned & clamped properly, then finished off on the drill press, then used my quality new dorma 3 stage taps (awesome BTW), countersunk the panel & installed, was perfect. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-326.jpg

The stands bottom panel just slides into place nicely.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-327.jpg

On with the pictures of the base & man am I glad this went ok, could have easily been a wreck with 1 faint wrong move, it was pretty intense doing this today so have no doubt doing all the rest of the fixings will be similar. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-328.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-329.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-330.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-331.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-332.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-333.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-334.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-335.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-336.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-337.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-338.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-339.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-340.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-341.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-342.jpg

So yeah only screws for the base are on the front small pieces, was a nice challenge but it's back to scroll sawing next time, these feet will get further finishing done on them but they are totally functional now which I'm happy with.

[SXRguyinMA]

you should bag up all your aluminum dust and scrap so I can turn it into a scrap yard and buy myself a new rig :eek:

stunning work as always :D

[Stonerboy779]

woah okay now I like them alot that looks great :D

[d_stilgar]

woah okay now I like them alot that looks great :D

You're eating your words now. ;) I was with you though. I wasn't sure I was going to like them until I saw the finished product. So nice!

[Stonerboy779]

You're eating your words now. ;) I was with you though. I wasn't sure I was going to like them until I saw the finished product. So nice!

Well I thought it was going to be fixed in place the way he had it stacked haha can't blame me for thinking it looked strange.

[Waynio]

you should bag up all your aluminum dust and scrap so I can turn it into a scrap yard and buy myself a new rig :eek:

stunning work as always :D
Hehe :D Thanks Will, yeah I've been scooping up any scraps that aren't of any use & bunging them all into containers & when it gets to certain weights I'll sell them, did think of making my own metallic paints with the dust lol. :D

Any scraps I think might be useful though I keep a big selection of them in the corner of the room, more than enough to do a load of smaller projects by now, it's been building up since my first scratch build. :banana:


woah okay now I like them alot that looks great :D
:D Thanks mate, understand why you thought that now. :)


You're eating your words now. ;) I was with you though. I wasn't sure I was going to like them until I saw the finished product. So nice!
Thanks mate, yeah gravity wouldn't let me show it dry fitted. :D


Well I thought it was going to be fixed in place the way he had it stacked haha can't blame me for thinking it looked strange.
:D:up:

[Fuganater]

Insane amount of work bud. Good job so far.

[_ferry_]

Nice, nice, nice!

Oh, and another nice ;)

[Waynio]

Insane amount of work bud. Good job so far.
Thanks mate, as long as I only go at this with a cool head so I do it all to plan it should continue like this. :D:crossed:


Nice, nice, nice!

Oh, and another nice ;)
Lol Cheers ferry. :):up:

The 2 drum sanders came today, 12.5mm & 25mm. :banana:

[Aldersan]

Amazing progress! It's starting to come together! Keep up the amazing work!

[Waynio]

Amazing progress! It's starting to come together! Keep up the amazing work!

Thanks Aldersan :) Just completed 1 of my to play games from a big list, I originally intended to mod a bit, game a bit, live a bit but up to now has all been mod a lot lol, trying to balance it all better & get back up to speed on gaming so I can enjoy new ones when they are new rather than carry on adding new ones & not getting around to playing them. :facepalm:

[Waynio]

Started on the HDD cage for the HTPC & started the fan mount stand, all 5mm black acrylic, also cleaned up the workshop (needed it). :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-343.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-344.jpg

Might get them stuck together before I go bed, might. :D


Ordered the rest of the mini-ITX parts, Asus E45M1-I DELUXE on-board CPU/GPU & Kingston HyperX Blu 8GB & 4x 20w per channel fan controller & because I don't trust fan controllers after a couple of meltdowns a dedicated 92mm fan to cool it, fan controller is for the gaming rig. I'm Broke again. :(:facepalm:

[Aldersan]

Oohhh shiny..also, goodies! Can't wait to see it all put together! Keep at it bud!

[Waynio]

Oohhh shiny..also, goodies! Can't wait to see it all put together! Keep at it bud!

Thanks Aldersan :) made more progress.

I should have gone bed lol, finished sticking at 5AM. :eek:

HDD's slot in place on plates, 4 HDD 1 SSD. I first seen this method done by oliverw92 on his POLARity (http://forums.bit-tech.net/showthread.php?t=184426) case mod, I liked how neat it was & said at the time I want to do that & now I am. :D

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-345.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-346.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-347.jpg

HDD cage almost done. :D

7AM HDD cage able to handle it.
Just done a loose fit test to see how it all looks together up to the stand... :yellow_green::D But no sneaky peaky yet. :D

[Waynio]

After doing a loose fit the other day & seeing it kind of together I just couldn't keep it to myself so while waiting for a delivery today I did it again & took a few pictures & remember all of this is fresh raw cuts that are to be cleaned up a lot & there are a few more decorative pieces to be made. :D
And yes the back panel is on the wrong way around & so is the PSU rather than have cables poke out the front. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-348.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-349.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-350.jpg

I'm not 100% sure but think the edges of most parts are like 0.3mm too big or about that so just need a faint sanding on edges, just glad nothing is too small because then I'd have a problem. :D

I was going to use some different methods for fixing things together but it's probably silly & not worth the extra effort so I'll do same old screws to begin with but the option will still be available for the alternative tool less version but screws will be visible in places but won't have to use a screw driver for maintenance other than securing expansion cards, everything else will click & slot in place by the time I call this complete which is still a long way off I think. ;)

[Aldersan]

That came together nicely! Great job, now you can see all your hard work beginning to pay off!

[Waynio]

That came together nicely! Great job, now you can see all your hard work beginning to pay off!

Thanks Aldersan yeah, nice to see how part of it will look now, just needed the hdd cage to fill the last level, should do the extra detail pieces next but need to decide wood or aluminium or even acrylic, decisions. :D

Just got the mini-ITX mobo, 8GB RAM. :D

Installed on the mobo tray & powered up to make sure all is ok & it is, the RAM goes perfect with it too, it's got the sweet efi bios on it too. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-351.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-352.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-353.jpg

I sliced a piece of the tip of my thumb off when cutting some bread earlier. :facepalm:

Hopefully the tip missing from my thumb won't prevent me from carrying on, was only a 3mm loss but will need to be well covered when doing anything for a bit while it repairs, just glad it wasn't more than what it was. :)http://i433.photobucket.com/albums/qq59/waynio_2008/bit-thumbsup1.gif

[billygoat333]

yikes! Must be quite the knife you use to cut bread!

[Waynio]

yikes! Must be quite the knife you use to cut bread!

Global knives & he keeps them sharp but the bread knife that's just sharp with teeth :eek: shouldn't have tried cutting the last slice so carelessly, went through with some force too. :facepalm:

The piece was just about hanging on so cleaned it up, disinfected & pressed it back down & wrapped up to hopefully let it heal, just hope I didn't damage any nerves, need the feeling for control.

[AmEv]

http://i433.photobucket.com/albums/qq59/waynio_2008/bit-thumbsup1.gif

WHERE did you find that smiley! :):up:

[Waynio]

WHERE did you find that smiley! :):up:
I modded the 1 from bit-tech in ms paint. :banana::D

[Stonerboy779]

Soooo good looking :)

[Waynio]

Soooo good looking :)
Thanks Stonerboy :):up:

Been letting my thumb recover & had some life stuff to sort out.

I was going to get modding again but spent most of Saturday designing so it can support a fan controller & a 92mm fan with grills to keep the controller cool, I like the solution. :D

Had to tweak the already cut front gamer panel in a way that I will be able to mod it & keep it looking good, the fan controller has black with coloured display with temps & speed readings, this should be a nice addition. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-354.png

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-355.png

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-356.png

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-359.png

Under the 92mm fan view from the HTPC.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-357.png

Full view
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-358.png

I will get the designs printed & stuck tomorrow & hopefully get on with this again. :)

[Waynio]

Long stupid story short, it's been a bad month not for the project but with my bro but things are straight again now other than a couple of injury's I picked up.

The past few days I've spent quite a bit of time getting everything spot on & ready to print including mounting points on some parts already made just so I have a very solid plan to follow where my efforts won't be a waste, all the curved bits & the fans needed extra design work so everything is ready to go forward now but the roof of it I still might put some extra work into as it's the only part that hasn't had much thought put into it, just been putting more into the internals & thought why just do 2 custom fans & why not the lot. :D

Decided to use clear acrylic for this now & also made the fan duct use acrylic also so the custom fans aren't hidden & kinda looks like they float, will be a mix of 1mm & 3mm acrylic so I'll make a gripping piece so the 1mm stuff isn't prone to getting damaged, the plan is so the duct piece easily slots tightly in/out of place with enough slack wire to allow putting it aside when doing any maintenance.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-360-1.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-361.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-362.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-363.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-364.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-365.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-366.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-367.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-368.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-369.jpg

CPU cooler will either be a Zalman CNPS12X because it cools nicely enough, is a triple fan out of the box & looks awesome or I'll just mod my prolimatech megahalems so it doesn't need the fiddly wire fan clips which I don't like.

The curved cover piece for the front of the HPTC I had no idea how to accurately do it in real life or make the cut out bit accurately in the design so knew it was 1 of the bits I was very unsure about, during the process of getting the fan cut out in the curved panel I learnt a few new skills so I'll be able to design patterns into curved panels from now, took me a while to figure it out but could do it nice & quick now. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-370.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-371.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-372.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-373.jpg

Also started using plugins on sketchup after cheapskate mentioning about them when I was trying to get accurate measurements of curved pieces, very handy 1 called flattery for flattening out curved panels, does it in segments of wherever the different angles are which makes for a totally accurate printable design of a curved piece with patterns inside it, so it all depends on my execution now. :D

Shame nothing was done during May so far but there is still just over a week left of it where I could do quite a bit & the little extra time I spent getting the design right also gave me a bit more recovery time, but I'd say I'm about as recovered as I'm gonna get for now, could be a long time before it's fully recovered & not so prone to extra damage.

So today I'll get toasted in the sun & tomorrow a cram packed week of modding. 8)

Lastly for this last concept update before the modding continues a look at how it was in February & how it looks now, I'll update my first post with the revised one also, the design has been a work in progress from the start even though I thought that's it with the first update. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-374.jpghttp://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-375.jpg

[Aldersan]

Been waiting for an update! Looking good, but can't wait to see the real thing! :D

[Waynio]

Been waiting for an update! Looking good, but can't wait to see the real thing! :D

Thanks Aldersan, I know it's been ages since my last real update of progress but things are starting to move now. :banana:

And I can't wait to see all this fixed together ASAP. :D:up:


Me & my running ahead of myself due to me getting seduced by the nice weather again :D:redface: I'll be stronger tomorrow to make sure I get well into this but I got as far as getting all the fan designs & curve pieces printed, cut, aligned & tacked together ready for sticking to materials so I'm right back where I was about 3 weeks ago but a few steps ahead ready for continuing tomorrow or later rather. :D


Printer friendly prep, all the fans & fan holders & all curved pieces converted to precise flat versions which will require me to be highly accurate on doing the curve pieces which should be fun doing correctly. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-376.jpg

Aligned & tacked together.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-377.jpg

More.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-378.jpg

Close up of a tacked together section.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-379.jpg

Remains.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-380.jpg

Result.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-381.jpg


Wooo Hoooooo the rusty wheels have started moving & this thing is rolling forward again at last, the past 3 or even 4 weeks have felt like absolutely ages. :D

[Aldersan]

Again, TONS of prep work, but it shows in your build quality!

[Waynio]

Again, TONS of prep work, but it shows in your build quality!

:) Cheers Aldersan & that's still not everything, man what a mod I went & designed. :facepalm:

This was a tough additional template to place perfectly on the front gamer panel but managed it.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-382.jpg

Cut out the tweak & just needed to add the bevel for the LCD on the fan controller, if only I could rewind to this point.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-383-1.jpg

Taken a big step back, screwed up the front gamer rig panel, stinger but my mistake was not using files for the bevel which would have been easier & quicker but instead used my scroll saw, up/down cutting I'm used to but angles ugh, need more practice, much more, just didn't use my noggin enough this time or I've got rusty at modding with the time out.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-384.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-385.jpg

It's a kind of an advanced bevel though because it's acrylic bevel joining up to the aluminium all while being flush fit so maybe it was just a bit difficult to do mixed with mod rust, already got the tweaked design of the panel printed again to re make it right after this post, got to have a modathon through the night & all tomorrow so I'll be leaning into the progress zone where I feel happier, neighbours are away for the weekend so don't have to worry about noise, I'll be aching tomorrow night but it'll be worth it. :D

Two good things though, all the templates are stuck to materials & got 1 new panel made. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-386.jpg

[Waynio]

These little cut outs again, :dead: they take some time to do, patience is thinner than it was early in the project so I mixed it up doing a bit on the front panel & then do 1 of the easier panels going back & forth, gave an ok feeling of making solid progress while fixing a botched panel rather than just re make the botched panel.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-387.jpg

Gamer bottom, applied a template to it for the mounting holes & 92mm fan hole.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-388.jpg

Filling panel & with it being a filling panel this is 1 of the many panels that will be put on a harsh diet once everything is together. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-389.jpg

Just taking a break & killing time while my mp3 player charges back up so thought may as well do a mini update. :)

[Waynio]

Drill helper in action.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-390.jpg

Takes the unpredictability of the drill bit wandering out of the bulls eye so thanks again Angel OD really helps hit the bulls eye every single time & easily, it's even far better than my cheap drill press which is prone to wandering away from the bulls eye so isn't a very useful drill press really, it can sway away as much as 2mm, only thing that would make the drill helper better is if it was stainless steel & a bit wider to be easier to clamp & so it stays in good form for longer so it can have it's permanent place alongside my rulers & squares so have ordered 2x 25mm x 10mm x 245mm flat bars to make a couple so I can use the 2 for drilling the centre of rods also. :D

I'm that happy with the drill helper I see it as an essential tool now so it's worth making a nice strong one that will last, aluminium ones need re making regular. Two of these will be made in stainless steel either tomorrow or the day after. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-391.jpg

While re making the front panel I was switching over to some of the 2mm parts but didn't take pictures of them all, final details like sanding edges completely flat are still needed to be done on them but next update I should have quite a bunch of parts made, the small bevel with an awkward corner bit I did with a small file I don't usually use but it did the job very nicely, just needs about another 3 hours of attention to the overall panel but I'll keep mixing it up so I'm making other parts at the same time which will keep my mind in a fresher state. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-392.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-393.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-394.jpg

Would have finished this panel & a bunch of others yesterday but I passed out when I went for what was meant to be a 10 minute break, was about 3/4 the way though a 30 odd hour modathon, the 30c temp helped put me to sleep also, just glad I didn't sit outside as I'd have got toasted. :D

Back to modding I go.

[AmEv]

You needed the sleep.

We'd rather have the project take longer than expected due to getting more sleep that you being permanently hospitalized from sleep deprivation, and the project never gets done.

[Waynio]

You needed the sleep.

We'd rather have the project take longer than expected due to getting more sleep that you being permanently hospitalized from sleep deprivation, and the project never gets done.

True :) it's just sometimes my sleep pattern goes right out of sync & I find the best way to fix it is stay up until the next night & then get a good sleep, neighbours were away so was able to mod through the night, I do listen to my body though when I need to. :):up:

Today I just dedicated to finishing the re make of the front panel & it's nice to be back in the progress zone. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-395.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-396.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-397.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-398.jpg

Tomorrow is easy parts time. :D:banana:

[AmEv]

How's this:

Next time I've got A: cash, and B: I see one of the famous Micron cases at a thrift shop, I'm sending it your way, because I know you're going to keep it awesome.

How's that sound?

[Waynio]

How's this:

Next time I've got A: cash, and B: I see one of the famous Micron cases at a thrift shop, I'm sending it your way, because I know you're going to keep it awesome.

How's that sound?
I'm a tiny bit confused by your comment AmEv, shipping from US to UK would be far higher cost than the case also. :D

I had to clear out all my old butchered retail cases about 2 years ago, picked through them all for anything useful though & put them in a box, was a sad day having to get rid, but they was all taking up a good bit of space so had to be done really, did have my first beige box built like a tank that went also, actually I gave that to 1 of the neighbors even further ago, they really made them very strong in the 90s & before then but thanks to the beige boxes modding started blooming. :):banana:


Weekend didn't quite go to plan but was fun, :) "was" set to do 2 very big sessions this weekend but kinda been looking forward to Max Payne 3 & when I went to the supermarket to stock up on coffee sugar & milk I seen it sat on the shelf while walking past the entertainment section & I just couldn't resist, was like a powerful magnet that pulled me towards it to buy it & completed last night early hours so got heavily side tracked by an awesome game, :D was a fun ride though & my system with single GTX 580 handled it perfectly on max settings at 2560x1440, many of the levels look amazing & the gun-play rocks, only used the matrix slow downs a couple of times when I was getting whooped too many times, more fun playing it raw. :D

Erm, sorry about that I'm 50/50 gamer/modder so can easily get distracted by awesome games, back on topic. :D


Started on making the custom fan frames, managed cutting it easy enough but the 2mm alu didn't have laser film on which helps to hold templates down & instead has the more typical flimsy plastic coating so when getting around to the final side it had risen flapping about & the template was useless so I fluffed up the cut pretty badly IMO.

Template side looks ok.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-400.jpg

Side view you can see how the template had risen enough to flap about while the blade goes up/down making it impossible to see what your doing properly.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-401.jpg

Template & backing removed which shows a nice big defect on the right side.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-402.jpg

If I'd have swerved away from the cut line to clear the impossible to see bit where I was cutting I'd have been able to file down the rest easily so I'll do that for all the others now but this 1 needs re doing. :)

These 2 2mm strip pieces are filler pieces for the gaming rig.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-403.jpg

On to the fan controller, no branding thank you. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-404.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-405.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-406.jpg

Panel I pre-drilled a bunch of days ago but finished off the drilling for the control knobs & cut out today.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-390.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-407.jpg

The stock one has 1mm sheet folded over connecting the unit to the front stock panel so I used spring washers to fill the spec & 6mm countersunk stainless steel screws.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-408.jpg

Altogether, another example of why I love digital callipers & printing designs, it's spot on, the protective film is staying on the LCD until it's ready for use & I might have a go at making custom control knobs also if I feel like it when adding finishing touches. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-409.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-410.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-411.jpg

Fan controller aligns to this bevelled bottom area once I get the acrylic cut & bevelled.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-394.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-398.jpg

I'm not going to say I'll do some tomorrow since I keep slipping on what I say I'll do & then don't for whatever reason but hopefully I will get back into regular updates tomorrow lol, been very herky jerky since May which was a bit of a bad month. :D

[AmEv]

^What I mean is, I'd strip the case bare, then ship the light box to you.

All at my expense.
(Unless you wanted to chip in some.. <_< >_>)

[mDust]

Freakin' wild! I have never seen anything like that (except maybe the fan openings as the windows in StarWars). The amount of work already put into it is unbelievable. You should get some sort of award for that...do they have a Nobel Prize for modding yet?

To be quite honest, I don't even like the case...but hear me out. It's a bit too wild for my taste. This is just my opinion, and too be fair, my opinion is pretty worthless in this scenario. My disliking it doesn't make it any less awesome, interesting, or inspiring. (In fact, a couple pics here inspired the shape of a case I was thinking about.) I do, however, like that 10mm alu and all the time and effort put into it...I can't even believe it was all done manually! *High five* I'm sure the pics can't even do those finished edges justice... +rep man! Keep up the awesome work!

I feel that we need a button to subscribe to all future projects!

[AmEv]

I feel that we need a button to subscribe to all future projects!

http://www.thebestcasescenario.com/forum/subscription.php?do=addsubscription&t=28404
http://www.thebestcasescenario.com/forum/profile.php?do=addlist&userlist=buddy&u=9485

:P

[Waynio]

^What I mean is, I'd strip the case bare, then ship the light box to you.

All at my expense.
(Unless you wanted to chip in some.. <_< >_>)
For me to mod or to preserve, think that's what I'm puzzled about :D can't be to preserve it, you wanna see me mod the original beige box that made people get into modding eh. :D:up:

I do like seeing what other modders do with them :) I also like how they are built like tanks.

If I did would you want it to remain beige but with a heavy load of modding done to it for a laugh. :D Be interesting to see if it was nicely doable really. :)

It is very possible I'll be doing my first public show case mod sometime soon though, recently acquired a Corsair R300 which is a budget case, cheaper the case, the better for modding into something great I think. :):up:


Freakin' wild! I have never seen anything like that (except maybe the fan openings as the windows in StarWars). The amount of work already put into it is unbelievable. You should get some sort of award for that...do they have a Nobel Prize for modding yet?

To be quite honest, I don't even like the case...but hear me out. It's a bit too wild for my taste. This is just my opinion, and too be fair, my opinion is pretty worthless in this scenario. My disliking it doesn't make it any less awesome, interesting, or inspiring. (In fact, a couple pics here inspired the shape of a case I was thinking about.) I do, however, like that 10mm alu and all the time and effort put into it...I can't even believe it was all done manually! *High five* I'm sure the pics can't even do those finished edges justice... +rep man! Keep up the awesome work!

I feel that we need a button to subscribe to all future projects!
Thanks Dust appreciated mate, to be honest even I don't know what to make of my own design lmao :D I set out firstly to do excellent functionality which I feel I have nailed, but :D the shell & styling which greets the eye first of all I wasn't really going in any direction other than thinking it was looking too plain & lacking detail & wanted it to look interesting so I kept adding more & more trying to wrap the pattern all around the case so it flowed nicely around it, I could pick a popular thing & do something based around it which wouldn't be so alien to people, when going themeless, minimal & classic looking seems to work very well but heavily detailed like this, the work load impresses people but mostly doesn't win for onlookers seeing it as too busy, I don't mind that though & understand it, it was always the functionality of modding that got me into it in the beginning of the hobby & been trying to make them look nicer but realised I don''t seem to manage that with the type of thing I like in a personal rig but in the process my skills have grown nicely & feel I could make whatever I want to now. :)

I'm sure I will have a go at a themed project some time though which won't be so alien to onlookers. :D

--
Update :)
Craig toyoracer mentioned about the distance of cut work earlier in the project & since then I've been curious to know & figured some new things out on sketchup, 1 bit being seeing the length of all edges.

I'll be going waaaaaay past 100 meters of cut work on this by the time it's complete, no wonder it's taken so long & still so much ahead, this is truly good scroll saw exercise though, incredibly dreary but good exercise which helps make things easier in the future, this is why it's so daunting going at the panels on this, you just know it takes a long time to do & you need a special mind-set to not think about that & just go at it else you can wind up thinking too much of how long it takes which is where I'm stuck at the moment, I had the same problem while doing the gamer side panels, I know the solution but it's moving to it that isn't easy. :D

Gamer side panels as expected are the craziest coming in at just shy of 15 meters each, this will be why they took like 2 massive sessions to do each one. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-412.jpg

But the craziest IMHO is yet to be done, the lowest front pattern is small 180mm x 86mm & weighs in at 7 meters of very intricate cutting, this piece was going to be in 3mm Maple wood which would have been easy & speedy to drill & cut but is now 3mm aluminium so think it's gonna be hell to do & I can easily see myself having big difficulties doing just the drilling alone on that because only a 1mm drill bit will be able to give access to many of the tight waves & here is the problem I keep breaking the 1mm bits when drilling 3mm aluminium with my tight budget drill press so a redesign of that part might be needed, I'll soon find out, hope I can drill it though without getting too many broken drill bits, I'm bound to get at least 1, they break real easily. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-413.jpg

It puts things into better perspective knowing how much actual distance I've been doing, gives me a good idea of how much I can get through in a certain amount of time so I could now go at it with a realistic goal checkpoint to reach before calling it a day but the thickness is a mystery factor if not worked before, this is for sure.

I was looking around for a good pedestal to put this on when it's done but I don't fancy paying £200+ for a nice one when I think of the materials I could buy instead with a lot less & I want to be sure it will be strong enough, this is first version so no doubt I'll develop it further but I think this will be the basic form of it. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-414.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-415.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-416.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-417.jpg

Looks even more strange now :alien: I'd say that's because this is the vanilla v0.1 but if I do do something like this I will make a 3mm panel that is like a tracing of the bottom of the rig so it slots in place when putting it on.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-418.jpg

Figured I'd better show some actual real stuff also. :D
2 extra fan frame pieces, they were made extra difficult to make with the templates coming loose, 1 more method to try for getting a good stick before I just stick them to the bare aluminium but I think that will give the best sticking power.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-419.jpg

Luckily I didn't see how the fan controller fits into the front panel so have something good to show. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-420.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-421.jpg

There is still an acrylic piece to be made that goes over the control knobs & continues the bevel edge to make a surrounding bevel round the display & gives the aluminium underneath a different tone.

More soon. :)

[Stonerboy779]

So it wasn't tall enough yet?

[Waynio]

So it wasn't tall enough yet?

Noooo lol. :D
With the pedestal it's 4 foot 5
HTPC - 400mm high === Gamer - 440mm high === Together - 840mm high === 249mm wide === 342mm deep
Pedestal 530mm high.

Due to Cleveland expressing some disappointment about the standard fan controller knobs which has an effect like being shot with a think deeper gun lol I looked around the net for something to replace them with, bought chrome dice & marbles then did a mock up in sketchup & I just didn't like the mock-up, might look better in reality but anyway I took to designing my own knobs to fix onto the stock ones.
These have good pointiness, they sit 4mm lower than stock & will look even lower to the panel due to the pinch type grip on them.

Hopefully these appeal more, they do to me so that's what matters most. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-422.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-423.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-424.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-425.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-426.jpg

Done some more designing on the pedestal, the form & function is complete now & it will be awesomely strong, only decorative stuff left to tweak on it now.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-427.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-428.jpg

Also designed a mounting sheet for the rig to slot into.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-429.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-430.jpg

I am really glad Cleveland pulled that trigger to zap the thought cogs to start them turning again because when looking around the net for things I could use, marbles really stood out for me, particular artful type ones hand made made by glass masters, I was like a kid in a sweet shop (but these days a retail riot) picking the right one out for this build, I was very tempted to go for one with colour but managed to stay on theme by keeping it neutral & I haven't given a power switch any thought at all other than same old vandal switches as a last minute function detail mounted wherever I could when it's done.

Here is a group picture of the bits I ordered, the 2 small marbles & chrome dice was an option for the fan controller that I doubt I'll go ahead with, the black & white marble they had sold it in the shop earlier that day but didn't get it updated in time on the site so they offered a refund for it or let me choose another 1 & let me go for one that was £5 more so I chose the same clear with detail one so will be able to pick which one looks most interesting & have a spare now, think this will be a regular feature in my projects starting from this one, such an awesome range to pick from & they will always looks different. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-431.jpg

Marbles ranging from 5p to £800 some really nice pieces of glass art here from £20 to £800 but £40+ ones are keen collectors items but if I was a millionaire I'd probably buy loads, :D there is a good range of really nice ones £20 to £40, I'll be a regular shopper here for the magic ingredient for these power switches. :)
http://www.houseofmarbles.com/

Dice, crazy enormous range of dice. :D
http://www.thediceshoponline.com/categories.asp

So I've worked out a really kickass idea for using awesome marbles as power switches & I'm sharing the idea before I've even made 1 because I'm so excited about it & can't keep it to myself without my brain melting & dribbling out of my ears. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-432.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-433.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-434.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-435.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-436.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-437.jpg

The marbles I'll be using are 40mm diameter & are hand made & I'll make them function like a vandal switches & here's the good bit, illumination & crazy interesting colours & shadows being cast from them, it will involve springs, a basic switch, a box to enclose it all & 5mm opal frosted acrylic formed into perfect fitting cups for the marbles, primary power indicator LED's, secondary LED's for HDD activity, could use different colour or slightly different or even the same but placed in different spots, I could also use layers of tinting film if they are too bright, I anticipate these power buttons to look & perform pretty incredible. :)

Should cost me no more than £30 to make this power button & £25 of that was for the marble so 3 times the price of a vandal switch but infinitely more awesome especially where I'll be mounting it. :D

Not really a good enough spot for this on the gamer rig sadly so I'll go with a typical vandal switch for that but I'll try to hide it away or might even use a chrome dice for a switch. :D
Front mount not a good idea.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-438.jpg

Top mount, bit too cramped to mount nicely so would work best closer to the top back.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-439.jpg

Did I express how awesome I think this power button will be :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-437.jpg

Workshop progress will continue ASAP, this update represents the past few days of thinking, designing & getting better at sketchup, learnt so much more on sketchup since starting this project & can keep it so I can realistically make whatever I design also. :D

[Waynio]

Extra bits came in. :)

Chrome dice.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-440.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-441.jpg

Marble.
Razer Lachesis pulse light on the mouse.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-442.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-443.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-444.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-445.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-446.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-447.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-447a.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-447b.jpg

Alarm clock LED.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-448.jpg

Standby light on TV.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-449.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-450.jpg

This power button will be awesome. :D

[Waynio]

Should hopefully be able to go at this regular again after such a good session, started 21:30PM last night & called it a day today at about 16:00 (took plenty of quick breaks) so feel I've got a good bit of my drive back to really get this back on now, lesson learnt, don't slack off during a project even if good things like marble power buttons do come to mind & with that in mind it's worth thinking of taking a month off a project midway though if it's a big project. :D


Curve panels for the gamer rig now ready & waiting to be bent & curved, yes I checked all the oval holes to make sure they work right & they do, if anything they might need bevelling slightly when it's curved to give a near seamless look or as close as I can get to that, I'll make an exaggerated tighter version of the curve for a curving jig to form it perfect which I'll do when I get some mdf. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-451.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-452.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-453.jpg

PSU box section panels with 92mm grill & straight air though, also did a little filing to do the rough cut outside edges since it was late to keep the noise down, these parts still need an angle bar job doing on them & I'm thinking of trying the popular file it with a square file to fold it over to reduce the number of parts.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-454.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-455.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-456.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-457.jpg

I somehow skipped taking a picture of the 140mm custom frame piece in progress but caught a couple of the 92mm fan, I stuck the templates directly to the aluminium because of lifting problems & they totally remained held down this way, hassle to clean off but worth it to be able to see what I'm cutting properly.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-458.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-459.jpg

By this time it was ok to use the noisy disc sander to finish off all the external edges to the lines.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-460.jpg

So now getting higher & moving into the gamer mobo area & started using an aluminium flat bar for a drill guide, easier to see the alignment & don't need a deep one for normal panels, this method is far more accurate than my drill press.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-461.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-462.jpg

Feels like the land of good progress within 24 hours. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-463.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-464.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-465.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-466.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-467.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-468.jpg


There are still a bunch of decorative panels to make for the HTPC I'm not exactly looking forward to cutting :D & the pci/io pieces which should be nice & easy with the saw & many more bits to do but next session I'll try to finish off the fan frames, got 4 more 2mm pieces for the 2 120mm fans to make & then 8 1mm ones, might do the rods for the frames also & make a few spares for in case I screw up drilling any.

I'll also try to get the power switch mechanism designed, ordered some of the needed bits, couple of Lian Li cable replacement kits, I like having writing on the plugs for what the cables are for & the switch will do fine for this, only thing I'll need to order is springs unless I can recycle some from some old battery taking device. :D

BTW I know, brightness a step or 2 or even 3 too high in the shots. :p

[Waynio]

Had last minute thoughts about the HTPC detail panels just as I was about to enter the workshop yesterday evening, :D so took to tweaking the design instead of more workshop progress all night until just a couple hours ago, one thing led to another & another & another & glad I did because the pattern didn't quite flow perfectly just like the gamer pattern panels didn't until I noticed it clearly when I took to cutting them, :D I've made it so it will be easier to do & better looking by using some contrast & extra layers. :)

New plan for the high detail panels is 2 1mm panels & colour them differently & use washers in-between to make up the extra 1mm.

Some old vs new pics, I love this contrast, looks different from every angle & can look crazy if using a bright hot colour on the inside edges.

Old
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-469.jpg
New
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-470.jpg
Old
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-471.jpg
New
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-472.jpg

Now rather than let my sleep pattern get screwed up I'll get back in the workshop & continue until the evening. :)

[AmEv]

Showoff :D

[Waynio]

Showoff :D

Hehe :D:up:

With some wanting to see this start coming together I measured everything relevant for the HTPC again to see how things are going because when I did the loose fit it a bit ago the height was a little off but all the parts I made was spot on, turns out it was the psu & optical making it 2.1mm higher than it should be.

So had some troubleshooting to do, I made the psu level 86mm for a perfect fit, with the stock grill it's 87.8mm, no good, bye bye stock grill.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-473.jpg

Not certain if the optical drive will be a problem but probably will be, it's 41.3mm instead of 41mm, the optical level has 41mm space but I might get away with it but it will be a ultra tight squeeze, but if not I'll have to sand the panel above the optical to give it that tiny bit of extra space so it can slide in/out easier, think I'll do this anyway to not put needless strain on the threads.

I fixed the design & applied a partial template to the bottom 2 levels which bring air in for the psu to make the hole be in the right place & removed the psu fan grill & tested some 1mm material in place of it & it will work so I made a replacement, same grill design as the others & I'll paint it matte black.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-474.jpghttp://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-475.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-476.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-477.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-478.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-479.jpg

I would have been busy busy a heck of a lot lately getting all the other panels done or giving it a very good shot to but instead was in a pickle of what to do to fix some bits that needed fixing, absolutely knackered already but I'll continue tomorrow refreshed. :)

Moving into 1mm cutting time & wow it's a heck of a change of pace, I have to be very careful because it cuts heaps faster. :D

Also turns out I need 5mm rods & 2mm, I can't get 2mm alu rods but can get 2mm craft wire but it comes on coils so I'll have to straighten it out perfectly.

Got some milling needs doing so I'll drill the heck out of the plate & finish off with files, the scraps of the 10mm plate have been really useful & got quite a bit. :)

[Fuganater]

Looking good!

[Waynio]

Looking good!
Thanks Fuganater. :):up:

For some reason I decided to do the last 4 2mm fan assembly panels instead of the front panels, I held off doing them until I come up with a better way to stick the templates so they wouldn't come loose & flap about while cutting, stick them directly to the aluminium, had to re do the sticker sheets since the ones I done earlier & stuck was very bubbled up & useless, here is this batch tacked together before I cut them with the scalpel.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-480.jpg

Only downside to this is it is more hassle to remove the sticker, have to scrape it off with finger nails & then rub paint thinner on & it cleans up perfectly, thank you Craig for the 2nd opinion on that. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-481.jpg

This what they look like after cleaning them with paint thinners. :banana:
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-482.jpg

All the 2mm fan frame panels to make 2x 140mm fans, 2x 120mm fans & a 92mm fan, got the same amount to do in 1mm now & 16x 19mm rods to cut, file, sand, drill, tap & file before I can assemble them together & then use the drum sander to really clean up all the edges. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-483.jpg

The PSU fan grill, I primed, wet sanded & coated matte black earlier today with spray cans, thought I'd show it as it is before I sand the internal edges to see if people think I should or not, it would highlight the pattern more with the contrast when seen at angles. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-484.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-485.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-486.jpg

Now I'll do the detail panels, tomorrow. :D

[Stonerboy779]

Would you ever consider doing commissioned fan grills? These things are serious works of art and look fantastic.

[Waynio]

Would you ever consider doing commissioned fan grills? These things are serious works of art and look fantastic.

I would, but I'd also prefer to sell the design to someone who makes batches & sells them, a good sized batch could be made much faster than I can make 1 of these, unless it's the fact these are hand made also though. :D

I said as much on bit-tech, maybe someone will come forward & propose something to make it happen but I don't know yet, I hinted at me being happy to let MNPCtech do them but I might have to just go & ask him to see if he's interested, basically offering to him first because he is great for modding. :)

Just made the ATX mobo tray & it's spot on, the slot at the top which is the point where the slide in/out function of the tray will secure in place, tested mounting a GPU in both pci express slots & the mobo slots are perfect, yay. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-487.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-488.jpg

And here is the motherboard that needs a clown honker nose power button to go with it. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-489.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-490.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-491.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-492.jpg

I may as well get making both the pci/io pieces today, be a few less technical pieces to make, only placed this retail one on it to see it lines up right. :D

[SXRguyinMA]

man the things I could make if I had the kinds of cash to spend on aluminum like you do :D

[Fuganater]

man the things I could make if I had the kinds of cash to spend on aluminum like you do :D

+1

[Waynio]

man the things I could make if I had the kinds of cash to spend on aluminum like you do :D
I'm not well off but I'm good at saving :D & to be honest projects like this keep me so busy it makes saving up even easier lol. :up:

Acrylic is more expensive than aluminium here for some reason. :?


+1
:D

So many cut outs but get on with it, :) the distance of cutting is very similar as the gamer side panel but in a very compressed small area & in 1mm aluminium so it's quicker to cut but still takes ages with having to be really careful to not deform the heck out of the material or miss-cut it, drill holes 1mm & 2mm.

Now get on with it. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-493.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-494.jpg

9 hours through the night.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-495.jpg

Cleaning with thinners gets it clean but also adds bits in the sharp corner gaps so need a tooth brush to get all the bits out after cleaning, not done in this picture.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-496.jpg

One down, one to go & some more bits. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-497.jpg

I'm taking a break, knew these pieces would take some effort & I still need to design the switch mechanism but it's already there in my head, just need to turn the vision into a working design & then make it. :D

Next time you see these pieces I hope to have them put together as 1 super duper panel With functioning marble switch. :D

[Waynio]

Since doing the high detail 1mm panel the other day I slacked off until last night & got rather busy. :D

Completing the 2nd high detail panel took about 5 hours this time, wasn't messing about or taking any breaks but this whole session represents 1AM to 1PM & it all holds together as 1 piece, still need to make the switch box to support the marble properly but that's all for this front piece other than cleaning up. :)

What was done...
Made the 2nd detail panel, filed & sanded the edges of the 10mm piece to be rounded, sanded the inside of the 10mm piece so the 3mm panel I cut out would fit in, took ages making it fit in, cut the back panel with basic circle, to align them perfectly for drilling mounting holes I simply took my time aligning them together right & clamped a piece of plate alu to it to give a good surface clamp & just done random mounting holes in the corners & tapped the 10mm panel & used 8mm countersunk screws from the inside with a bunch of 1mm thick washers to create gaps between the panels.

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-498.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-499.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-500.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-501.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-510.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-511.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-512.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-513.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-514.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-515.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-516.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-517.jpg

I really like this piece. :D

But guttedly I just noticed the 3mm panel placed inside the 10mm panel isn't aligned correctly due to making the hole bigger so it would fit in so I'll need to remake the 10mm piece & the 3mm piece. :( Oh well, worth redoing I believe. :)

The heck with it I'll see if I have the spare 10mm & if I have I'll do it now. :)

[Waynio]

Figured a good solution for the hiccup, cut where the red lines are.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-518.jpg

To be honest I was going to have the inset 3mm panel a bit further in rather than just plugged in the end so I think I'll cut where the red lines are & make 1 more panel like the faulty one but without the extra details but give the inside edge a bevel all around simply making it even more awesome, filling the gaps & having the ring where it should be. :banana:

I have options now. :bunny:

[Fuganater]

sooooooooooooooooo.....

Whats the over/under on how much this thing is gonna weigh?

[Waynio]

sooooooooooooooooo.....

Whats the over/under on how much this thing is gonna weigh?

I have no idea yet mate :D but if it is heavy I'll be lightening it up a nice bit by cutting bits out but in a way so it retains it's strength, be nice if I can get it close to the weight of a regular retail case but miles stronger. :)

[Waynio]

Traced around the insides of the 10mm panel shape so I can make a blank perfect fit panel before I complete the fix, ready for continuing now.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-519.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-520.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-521.jpg

Think I'll do all the set in pieces like this now, more straight forward.

[Stonerboy779]

So much awesome for just one power switch keep up the good work

[985323]

that psu fan cover is Epic!

[Waynio]

So much awesome for just one power switch keep up the good work
Thanks mate, quite a bit for a tiny bit but it's worth it. :):up:


that psu fan cover is Epic!
Cheers mate. :)

Fixing that 3mm panel so it aligned properly for the marble power button was difficult, the difficult part of it was getting the template stuck in the precise needed spot.

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-522.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-523.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-524.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-525.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-526.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-527.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-528.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-529.jpg

Anyway any other inset pieces don't need such strict alignment thank goodness so everything from here should be a bit more straight forward.
http://www.freesmileys.org/smileys/smiley-basic/chaplin.gif

[jdbnsn]

You are a true artist sir, inspiring, masterful work my friend!

[Waynio]

You are a true artist sir, inspiring, masterful work my friend!
Thank you jdbnsn, accidental artist, never originally set out to find myself on a road to trying to do stuff like this. :D:up:
The reason of the high detail is I just wanted a case that would make me not believe I actually made it every time I see it lol, :D think I'm on track still. :)

Got some prepping done for cutting the 4 HTPC side contrast panels & made a little start on them, once they are cut & cleaned up they are ready to mount, I also worked the fixing of the layers before cutting them because I really wouldn't fancy trying to drill these frail panels once they are cut, then have 6 smaller 3mm detail inset panels to make.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-530.jpg

Drilled access holes on both ends so I can work it better, kinda like a beat'em'up game where your used to playing on 1 particular side, can do both but seem to find it more familiar once you get used to following the cut line, the countersunk mounting holes in the corners didn't quite align properly to the panel I tapped so countersunk a little further so it gives a touch of wiggle room to align properly. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-531.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-532.jpg

Probably the most boring update of the log but I'm just posting this now so it is known progress is still rolling but I had a couple days off due to lacking energy & focus so been recovering, very important to do that when not feeling on form else I'd screw something up. :D

I intend to get back into it now that I just have a big cutting session ahead I need to focus on, no idea how long these will take but they are only 1mm thick & cut easy but I do need to be careful to not mangle them up, that's the difficult part. :)

And today I'm 12,775 days old. :D:eek:

[Stonerboy779]

Happy 35th crack a cold one and take a break from your work :D

[mDust]

that psu fan cover is Epic!

No, it's all epic.

Waynio, when you described this as 'alien,' I think that's just it. It reminds me of what I might see on a UFO post abduction. It scares my subconscious. :D

Also, happy belated b-day. Keep up the lunacy.:up:

[Waynio]

Happy 35th crack a cold one and take a break from your work :D
Cheers Stonerboy779 :D sorry for being out of it since my birthday, I got plastered & I some how woke up in Hawaii & looked like there was a beach party been going on so had to find my way home by sneaking onto aeroplanes & going to random countries until things looked familiar & then a long walk home. :banana:


No, it's all epic.

Waynio, when you described this as 'alien,' I think that's just it. It reminds me of what I might see on a UFO post abduction. It scares my subconscious. :D

Also, happy belated b-day. Keep up the lunacy.:up:
:D Cheers mDust will do mate. :):up:

Previously on Waynio has an update to show...

It was a boring update.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-532.jpg


Now...

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-534.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-535.jpg

Yes, another boring update, 1 down 3 to go of these. :)

But...

reikmaharg2 on bit-tech creator of Silent fibreglass PC (http://forums.bit-tech.net/showthread.php?t=164675) & Blue Horizon (http://forums.bit-tech.net/showthread.php?t=190657) offered help on making a super duper light mod called the Spindicator & made the complicated part for me. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-533.jpg

I've got my soldering kit & LED's ordered & should have them soon. :)

Here is a video of it in action.
Reoi6jfjT2o

[Stonerboy779]

OMG I really want an activity light like that, that is awesome.

[Waynio]

OMG I really want an activity light like that, that is awesome.
There must be a market for this type of stuff even if it was just modders, hopefully someone would step up to do cool bits like that & keep it so they can be used anyway the modder sees fit. :up:

Got the secondary layer cut & fixed the 2 together to the 3mm panel with washers inbetween them, here is a bunch of pics of it because I won't post any more updates until the other side is done. :D

Enjoy the wavy line trippage. :alien::up: (been told they make peoples eyes go funny :D)

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-536.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-537.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-538.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-539.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-540.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-541.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-542.jpg

[Waynio]

I seem to be making nice progress again. :)

Got the last 2 of 4 internal dual layer panels cut & cleaned overnight, they just need sanding to remove any scratches, I'm happy with them. :)

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-543.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-544.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-545.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-546.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-547.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-548.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-549.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-550.jpg

Wonder if I can keep this up every day, hope so. :D:crossed:

[msmrx57]

Looking awesome as ever! :up:

I don't know about the eyes going trippy from looking at them, but I imagine my eyes would go all trippy staring at the line while cutting them.

[Stonerboy779]

You know its hard to believe this is the first time you have done something like this, I know you have done aluminum scratch builds before but to this insane level of detail no. Still amazed that this is by hand and not cnc milled, keep up the amazing work on this piece of art.

[Waynio]

Looking awesome as ever! :up:

I don't know about the eyes going trippy from looking at them, but I imagine my eyes would go all trippy staring at the line while cutting them.
Cheers msmrx57 :) some people do struggle operating a scroll saw for long times driving them mad with boredom, I'm just keeping my eye on the goal & it's working, good lighting helps a lot, the daylight bulb I use is perfect for it. :D


You know its hard to believe this is the first time you have done something like this, I know you have done aluminum scratch builds before but to this insane level of detail no. Still amazed that this is by hand and not cnc milled, keep up the amazing work on this piece of art.
Crazy determination really :D the real difficult bit was getting my head around the amount of cut work needed doing, too easy to think about can I be bothered doing all that, :eek::facepalm: just have to get stuck into it. :):up:


Before I could go & make the inset panels for the stand sides I had to smooth the 10mm panels now or leave them rough so been smoothing the inside edges for the best part of Sunday, still needs more perfecting on the smoothing particularly in the corners where the drum sander couldn't reach but the bulk of it is done & should be insignificant what will be removed later to affect the fit of the inset panels, nice & smooth all over the internal edges though but not a uniform finish in the corners, I'll sort that at a later time but they are now ready for making the inset panels.

Drum sander all the way would have taken too long & probably burn my drill out so got the files out & took the bulk of the teeth marks out so all the edges just needed a final smoothing with the drum sander & a bit of sandpaper on a file.

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-551.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-552.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-553.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-554.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-555.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-556.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-557.jpg

I hope to get right back onto this later on Monday.

[Stonerboy779]

Do you reckon you would have the patience to work out just how many meters of cuts you have made?

[Waynio]

Do you reckon you would have the patience to work out just how many meters of cuts you have made?
I'll tally it up once it's all done :D can quickly do it in sketchup, but it wouldn't be accounting for bits that didn't pass quality control, there has been a few. :D

More progress.

With finding how some things still need that bit of manual touch on marking from the front detail marble panel, I did the same on the templates for the inset pieces to make life a touch easier.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-558.jpg

Used some decent scrap 3mm & roughly cut them out, roughly because I knew I'd need to file to make a perfect fit for them all.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-559.jpg

Whole lot of file, check, file, check etc.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-560.jpg

Until yay they all fit perfect.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-561.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-562.jpg

Pop them all out & drill start holes.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-563.jpg



I got 2 of the panels patterns cut out but I really needed a rest which I'm going to have now, back was aching like crazy so gonna have a little nap & then get back onto it. :)

[Waynio]

Finished cutting the 3mm inset panels & would have done this update at 8PM but I passed out while sorting through the pictures & woke up at 2AM lol.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-564.jpg

Scraped the templates off & then cleaned off the glue with paint thinners & scrubbed with a brush in hot soapy water & dried.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-565.jpg

Slotted them all into their homes, they slip in nicely & then push them so they go in fully with a little added pressure.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-566.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-567.jpg

Then thought let's see what they look like with the other side panel bits.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-568.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-569.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-570.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-571.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-572.jpg

Then thought why the heck not clean up the table to do another loose fit of the HTPC & stand.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-573.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-574.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-575.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-576.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-577.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-578.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-579.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-580.jpg

Now I can work on the power button design, once that is designed I can complete the Spindicator also, the most significant cut work to be done now is completing the custom fans & I might re make any acrylic bits because the adhesive was well past it's best so any flat pieces stuck together could be done much better, edge to surface bits are fine though & I got some new tensol 12.

I think because I left most if not all fixing together points out of the early design I'll go freestyle on that & use a good adhesive so parts stay exactly where I want them to & then drill so everything goes together perfectly & then remove the adhesive so I'll have to use one I know is strong but can be separated with the right methods, araldite rapid steel I've used before & is strong for something like that & it just requires heating with a heat gun & slide a razor between the joints & it does the trick.

[AmEv]

Lookin' good! :)

[Stonerboy779]

Now that you can see it all coming together it is so god damn sexy

[Waynio]

Lookin' good! :)
Thanks AmEv :):up:


Now that you can see it all coming together it is so god damn sexy
:D Cheers Stonerboy779, once I get this front switch made I will just have to make the back pci/io piece & then fix the HTPC & stand together, can't wait so I'll get pushing on now. :up:

Needed a massive countersink bit to get the marble flush or close to flush to the inset pattern panel, the marble is 38mm but big countersinks at 55mm cost £60 & then another £30 to £70 for a chuck with 20mm capacity & not willing to spend money like that for a rare tasks bit so I filed & drum sanded as a cheap alternative, did the job, now I can design the switch mechanism. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-581.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-582.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-583.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-584.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-585.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-586.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-587.jpg

Got the 4mm acrylic rod, got the m4 washers & springs so yes, it's time to work out the design of how this switch works.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-588.jpg

More soon. :)

[Fuganater]

That switch is gonna look sick. Will it be backlit?

[Waynio]

That switch is gonna look sick. Will it be backlit?
:D Thanks Fuganater, it will be lit with this beauty. :bunny:
Reoi6jfjT2o

[Waynio]

So, it's a 10mm spring compressed to 5mm so it stays forced into place so not loose & only have to press it 2mm in to switch it, 2x 0.9mm m4 nylon washers, 4mm acrylic rod, 3mm opal frosted acrylic sheet, 2mm acrylic sheet, Aluminium tube, 2mm aluminium sheet, 10mm aluminium plate, lian li switch.

Had trouble making it fit in but just about got to a point where it should work. :)

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-589.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-590.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-591.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-592.jpg

Just over 4mm space between the switch & PSU, extremely close.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-593.jpg

I'm done for today though.

[Waynio]

Improved the design & got it ready for the spindicator & managed to make it less deep so has a touch more space again, lol about 3mm extra space but it all makes a difference. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-594.jpg

Got it printed, had a good rest, caught a few rays from the sun so feeling gooooood, time to get busy until I have a good scoop of progress. :)

Next update I aim to do the back pci/io pieces for the HTPC & gamer rig, get this switch assembly made & fixed together & have the soldering done for the spindicator, I'll save the spindicator until last though because I might have to ask Keir about the negative part of the LED's again, might. :D

[Waynio]

Mini update while I take a break.

Chop saw time, :D I need to figure out exactly where I need to place the piece to be cut, also the clamp is a bad combination with the mitre guide because the clamp has decent force to hold things in place but the mitre guide is an easy push over so throws it off whatever angle you set it at so I recognised this & fixed the angle & only clamped so it was touching & held it manually, helped do a straight cut & wow it blitzed through this 45mm pipe with 3.2mm thick walls, took about 3 seconds or less & safety glasses should be worn using this as chips fly everywhere, I will mod this tool at a later date for the clamp & guide combo to function better as well as add a marker for where it actually cuts.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-595.jpg

Like said I need to figure out exactly where to place pieces to cut, had about 5 or 6mm excess I had to file & sand down to get it correct length, nice & square.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-596.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-597.jpg

On to the design.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-598.jpg

This is another nice thing about the scroll saw with 760mm throat I can cut a slither off a 1000mm panel easily by doing half 1 way & flip it around & go at the other side but I only needed a tiny bit off this sheet of acrylic lol. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-599.jpg

Used scraps for the aluminium bits.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-600.jpg

10mm aluminium takes some time to cut so I just took the needed piece off & got busy with files.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-601.jpg

Using that sweet precision helper for drilling on both the 2mm alu parts.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-602.jpg

Because it's 4 layers that need the same holes I completed 1 of the 2mm alu ones & then aligned that to do the acrylic ones & quickly got it drilled & because the other alu one was on the same panel I decided to just do that one too but same as the first one.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-603.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-604.jpg

All the needed bits with switch slotted in.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-605.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-606.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-607.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-608.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-609.jpg

I need to get the multi layer front panel mounted to the bottom HTPC panel before I fix the switch parts together so it functions 100% spot on.

Next up, pci/io pieces & I'll get back to completing this switch when I get to fixing the pci/io pieces together, should have another update in a pile more hours. :D

[Fuganater]

That button is going to be sick!

[Waynio]

That button is going to be sick!
:D:up: Can't wait to have it fixed together & the spindicator mod placed in it, hopefully very soon. :up:

Didn't meet the goal of completing the switch & PCI/IO pieces but.

PCI/IO pieces, 1 low profile for the HTPC & 1 standard ATX for the gamer rig.

Started first by printing, cutting, tacking together the templates & I made 2 for 2 slightly different aluminium panels on each one so the IO shield can pop in/out properly & just the 1 for the triple layer acrylic sandwiches which I stuck on the outer layer of the sandwich & roughly cut around it & drew around the master one onto the other layers & stuck together with tensol 12 acrylic adhesive & left them clamped for a few hours, I moved it around so it was 100% caked & squeezing out of the seams on the joining surfaces.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-610.jpg

While waiting for the adhesive to get an awesome bond I focused on doing the 1mm aluminium panels.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-611.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-612.jpg

Cutting the 13mm acrylic sandwiches proved tricky, when using normal blades they would get hot pretty fast even on a slow speed & start melting the acrylic causing some very unwanted problems of the blade going in any direction it wanted to with ease & melting the greenish dust from the black acrylic onto the opal frosted stuff making it look a heck of a mess instead of like a liquorice allsort lol, so I had to drill bigger holes so I could get a modded band saw blade in which still gets hot but not as fast & gets further before it needs a cool down, after cutting it all out I had a good bit of removing that dirty green mess away with files & razors which made my nice cuts dull full of uneven levels & requiring much more finishing, I want to get them to a shiny polished state so still have my work cut out on these.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-613.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-614.jpg

Loosely fit together, I like them & can picture how sweet they will look if I do polish the acrylic edges & polish the aluminium, they still need mounting holes adding & brass thread inserts pushing in, Ill do the mounting holes next.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-615.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-616.jpg

Would have posted this at 8PM but I desperately needed a nap or it was a natural hangover coming my way drooling into my keyboard lol. :D

[Waynio]

Just finished doing these, started yesterday evening but had a few hours of breaks.

Cluster pictures because there was 25. :)

Placed some masking tape on a square & marked where the blade comes down on the chop saw for easy aligning.
Left near 2mm excess to be safe & filed & used the disc sander to get it the perfect size needed.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-617.jpg

Drill helper idea being used for drilling the dead centre of rods & then finishing off in the drill press, I'm calling this poor mans lathe. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-618.jpg

Boring fan control knobs.
Cut a 6mm strip of card & wrapped it around the bottom of the knobs & marked a line around it, the bulky bit needs to be 10mm high, the smaller bit needs to be 6mm high.
Whole lot of filing until it's good enough.
Getting the same depth of hole on them all I perfected 1 & then used a pencil to mark where the needed depth should be for the others & did bit by bit until they were all good.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-619.jpg

Printed the model from different perspectives as a rough guide & got busy with appropriate files until they were good.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-620.jpg

Woooo, :D just need smoothing off on the drum sander now. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-621.jpg

End result but I will perfect these before I get them anodised & once anodised I'll re sand the sharp arrows for a sweet contrast.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-622.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-623.jpg

Awesome, nice to have those done with. :D

[Stonerboy779]

You milled them by hand......

WOW this just gets better and better and better.

[Waynio]

You milled them by hand......

WOW this just gets better and better and better.

Was a little worried I just wouldn't be able to work them good enough with only being 15mm diameter x 16mm but thanks to making them as 1 piece instead of 2 I was able to place them in the vice on the end, nice to have another big ish session out of the way.

Internal plans are mostly simple but might up the features, might :D cheers Stonerboy779. :):up:

[msmrx57]

You milled them by hand......

WOW this just gets better and better and better.

:stupid:
What he said. :eek:

[Waynio]

:stupid:
What he said. :eek:

:D Thanks msmrx57 :)

Played sleeping dogs to death :D time to mod on. :):up:

Drilled & heat pressed brass thread inserts into the rear IO pieces with the soldering iron, the inserts are 4.3mm diameter by 5mm long, I drilled 4mm holes & placed a marker on the drill bit so I knew where to stop so it wouldn't go all the way through the 7mm thickness, took it to about 1mm short of drilling straight through so they are nice & neat. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-624.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-625.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-626.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-627.jpg

Time to move forward with this switch.
I find clamping pieces to what I'm fixing to to be most accurate way when you didn't cover that part of the design with intentions of just bunging it all together when the time is right but make sure it's square before going forward. :D
Bottom, the blue tape is a quick rough guide for the 10mm panels so I just drill in the middle, did 1 on both ends.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-628.jpg

Top fixing, same as bottom.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-629.jpg

Tapping.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-630.jpg

Woo hoo, the marble & switch case is loose fit for now & I needed to sand nearly 3mm off the bottom of the 10mm piece which supports the switch in the correct place, took a while to get this done right. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-631.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-632.jpg

Here I drilled & tapped & countersunk the rear 2mm piece into the 10mm support, the gap you see is the resistance the switch has got from the spring & rod inside, the support piece needs fixing to the bottom panel but I was far too tired to carry on.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-633.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-634.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-635.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-636.jpg

Doesn't look like much done but I had no plans for doing the fixing together so had to be ultra careful to not botch any of the work gone into it so far, more soon. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-637.jpg

[Fuganater]

Nice to see it being put together.

[Waynio]

Nice to see it being put together.

It sure is :D thought I'd never get to it lol.

If the pictures aren't showing in this update it's something to do with photobucket having problems which surfaced on the 2nd & they are still having problems.

Guess an update is waaaaay overdue, :D tiny update due to a fat chunk of idling but an update, been having to rediscover improvising & patience with not following a script now so the stabilisers are off lol. :)

Had to countersink the steel washers for the HTPC side layer panels so they don't take up extra unwanted thickness like they were due to the wave detail panels being 1mm thick & ideally you need 2mm for a good countersink with m3 screws, had to place them in the vice by using a small file to guide 8 of them in place 1 at a time.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-638.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-639.jpg

Fixed the 10mm HTPC sides to the base so is a little more together, the layer panels slide into place from the rear for easy maintenance, just remove the back panel & front fan which slots in place & slide the detail panels out which leaves room for hands to reach in & tweak things. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-640.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-641.jpg

Here is the awesomely assembled spindicator done by reikmaharg2 for me, I'm pretty sure the project would be lacking that extra touch of awesome if this didn't happen so thanks mate appreciated, :) I also learnt the fist basic skill modders need when stepping up to electronics, soldering :D for keeping the wires numbered I prodded sharpie marker dots on them lol, either that or a lot of fun having to run them in sequence to find the right order after soldering which would make for messy wire work. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-642.jpg

I wasn't 100% sure where the negative stems of the LED's should go on the assembly & just had a vague idea even though he explained to me lol, so used an AC Ryan molex pass through adapter with a wire crimped & soldered in place which I will run to the negative 12 to 1 wire for 0v, kier acknowledged that as being fine for the negative legs, so that's the main assembly waiting to be joined to the LED's. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-643.jpg

So, made a start on the spindicator LED wire work & here showing the LED's plugged into place after I countersunk the exterior side so they don't bulge out at all & to make sure everything aligns correct, it does, or did after 2 of the holes needed drilling due to a super faint misalignment but got it done with minimal fuss. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-644.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-645.jpg

My soldering used to be awesomely terrible, I found this surprisingly easy to do, an OK soldering iron with heat control & flux paste & helping hands really changed that pretty much instantly like magic, flux paste is magic for soldering. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-646.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-647.jpg

And plugged back in place but I don't like what I did for the LED negative stem wire work on the LED end, soldering is fine but heck of a wire mess taking up valuable space for the 12 to 1 wire with the way I did that so I'll remove them & do those again while it's mounted in place to make it neater, I need heat shrink for it though before I fully solder everything together but I ordered some yesterday from phenoptix & it's been sent out so hopefully I'll get the switch & light complete this week with a video showing it in action but don't hold me to that. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-648.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-649.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-650.jpg

Been doing lots of thinking about many things, 1 of the things is I might have come up with a very nice idea for colouring this thing that I can do myself & isn't hazardous & really cheap, will be good wearing but I need to run some tests first to make sure the theory works, if it does I think I have a very sweet idea to share or a total flop, it'll be 1 or the other. :D

[BS Mods]

Great work as usual! I've been slacking on commenting on your awesomeness and I apologize. :twisted:

[Stonerboy779]

cannot wait to see a video of the button :)

[Waynio]

Great work as usual! I've been slacking on commenting on your awesomeness and I apologize. :twisted:
It has been a ton of just cutting so it's understandable, hopefully won't be far off before it's altogether now, cheers. :D:up:


cannot wait to see a video of the button :)
Me too mate. :D

Was thinking of mixing good inks or clothes dye with metal lacquer, the same stuff I brushed all over stealthlow, it has kept it all in very nice condition so felt like revisiting the idea to make it work.

Update on the ink idea, I added empty mixing bottles, syringes, main ink colours to make any colour & metal lacquer & looked at the price of just short of £40 & backed away from it thinking that's a bit of an expensive experiment really, I'd love to try it but not that much, that £40 could go towards a nice anodising job. :D

I do think the ink mixed with metal lacquer could work though but just don't know how well it would work without doing a couple of tests so the idea is there if anyone wants to give it a try but do it on scrap if you do just to be safe. :)

I also think maybe the metal lacquer might be usable as a clear primer for candy paint but not sure without testing, it does make a nice protective layer that is negligible on thickness yet offering good protection.

[Waynio]

Design update before the real update tomorrow. :)

Been designing most of the week, the stand & HTPC is going to get heavily worked on during through the night into Sunday evening, I'll be aiming to have a nice update posted late on Sunday evening.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-651.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-652.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-653.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-654.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-655.jpg

Gaming rig has been tweaked a good bit too internally, frame work massively improved & both 120 fans are now intakes without the ducts for more space & will allow for a normal none flush fit window if I decide to have side windows still but that's not likely when these panels can act like nice big vents, top window will be removable also but will be flush fit & so will the front windows still.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-656.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-657.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-658.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-659.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-660.jpg

The Zalman cooler. :( & :)
The :(
Base of the heatsink has a terrible wonky see saw effect but this gives me high hopes for awesome temps after I'm done with it going off the reviews I've seen on it fresh out of the box.
At least 1 of the heatpipes needs carefully filing down, I couldn't believe it that a fault like that passed QC for a premium air cooler but anyway I'll file any bad bits down & lap the hell out of it until it's real nice & super flat hopefully not going so far I sand into the heatpipe & wreck the thing, I should very likely request an exchange but I'm willing to make it work & finish Zalmans job for them. :neutral:

The :)
I took the plastic piece off the cooler & got busy making an accurate model of it, this will really test my filing skills to the limit, the fan control knobs was a warm up compared to this thing. :D

The zalman future car stunt show a split second before a crossing barrel roll went...
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-661.jpg

Awfully miscalculated, polygons mangled together about to drop on top of the 2 below. :eek:
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-662.jpg

Luckily the 2 doing the brave deed of letting them jump over them have an instant turbo boost to get away from the clump of mangled metal above but both flipped over from the crazy instant speed which couldn't be handled.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-663.jpg

Process of it developing while taking all the measurements with my trusty digital callipers.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-664.jpg

:D So I have a choice of 2 flavours, think I'll go with the rounded bits because the heavily angular one might be a bit too difficult if not impossible with files lol, both will be but yeah, the rounded one should be a fraction easier, the upper side I'm not really concerned about, it's the underside which might prove to be really difficult with scoop files (don't know what the proper name for them are). :)


I'll make it from a chunk of 10mm plate alu but first up is the stand & HTPC, I will update Sunday evening with how it all went but either way this is going to really progress now. :)

I have also had enough of photobucket nagging me each month to upgrade to pro so I bought a 2 year sub so I'd better make good use of it. :D

[Waynio]

Zalman stunt car show, what was I thinking lol. :D:facepalm:

Not the update I was hoping to post.

I'll come clean, I've not been getting much done at all feeling too demotivated (think I just needed a little time out, this project is kicking my rear all over the place lol) so absolutely nowhere near the point of what I was hoping to get done for my 4000th post on bit-tech but that was making me avoid posting far too much & there is much to comment on in other logs & new ones, also need to make the "workshop" more of a workshop that isn't prone to turning into a big game of twister & where's wally insane edition where you need a microscope when trying to find misplaced bits. :D


Again with that flipping spindicator?, fraid so & we’re not there yet lol. :D

When I went to do the new wire work on the spindicator after getting some get up & go to continue with white LED's (3rd time doing the soldering BTW) I thought that copper ring idea was possibly a far fetched silly idea that would be near impossible to do & in fact a great doable idea suggested by Keir for connecting all the negative LED legs for the spindicator so went ahead measured & designed/printed it & got busy making it out of 1mm copper sheet.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-665.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-666.jpg

Snipping LED legs.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-667.jpg

Soldering wires of same length to the positive legs.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-668.jpg

This bit was difficult & took the longest lining up all 12 legs through the 1mm holes of the copper ring, was a little frustrating. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-669.jpg

But managed it & then soldered it in place along with a wire to go to the negative wire, the heat shrink wasn't good enough for making a snug fit so had to think of something else so I ordered some liquid electrical tape which I'll brush on any exposed joints (hopefully have that tomorrow).
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-670.jpg

The colour discs for changing the spindicator colours, made these from coloured transparent vinyl's (bought a bunch of a4 sheets) & 1mm acrylic sheet & will easily be as good as certain coloured LED's with the diffusion from the opal frosted acrylic (I hope :D) & are relatively easy to change the colours but not easy enough to change without some effort so plenty of testing will be done to find my favourite colour once it's whirling.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-671.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-672.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-673.jpg

Also added 2 extra plain discs to make the switch need a tiny push instead of a fairly long push to function but might switch that for 1 because I think 2mm extra will be the perfect addition instead of 3mm, as it is it only requires a very faint push.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-674.jpg

How it looks from behind when installed, looks a bit messy at the moment but it won't once I get it connected to the spindicator & use liquid electrical tape to keep solder joints from shorting out & get the lengths to perfect length & neatly routed fixed in place.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-675.jpg

Space, did I mention how little there will be between the switch & PSU, look at the huge gap, spindicator was only just possible to be part of the marble switch. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-675a.jpg
I'll likely make a PSU back plate that mounts to the psu & back panel to give a pinch of space, good thing I don't need to use the modular cables for the HTPC, the gap you see on the switch house is due to having 1 too many 1mm discs in the pipe so it's forcing it over a touch like said the marble only needs a faint push to function, this will change.



Decided to have a go at getting the Zalman CNPS12X Ultimate Performance Triple Fan CPU Cooler base flat because it was a very long way away from flat & had a really bad see saw effect because of 1 of the heat pipes in the middle being at a higher level than the others which created a 1mm see saw, my advice to anyone buying 1 of these coolers, put it on a surface you know is flat & check it out to see if it has a nasty see saw effect & then get something like a metal ruler to check the base out carefully visually, if it isn't flat get it exchanged rather than try to flatten it, I'll show why.

I have never had to file a heat sink base before, had to lap them before now but never had to file, that's as bad a sign as you can get of quality control gone AWOL.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-676.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-677.jpg

So, once I got it flat from filing I wanted to go a little further by now lapping it, I should have settled for a not flat base but a flatter than what it was base, this fat chunk of 10mm thick aluminium with smooth edges has been serving me nicely for sanding things perfectly flat.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-678.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-679.jpg

I kept checking for sweet flatness & it has a slight concave base also as a nice bonus on top of the wonky base & because of how much I had to file down it must have left virtually no pipe left to sand so a tiny hole formed on the worst heat pipe & a little liquid had come out, I knew it was knackered at this point so continued to see how bad it would get if I made the base completely flat just to see how badly made the base is on this.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-680.jpg

Not good at all as it happens, I noticed another wet spot, joy.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-681.jpg

Oh yeah, this is what happens when you make the base of this cooler perfectly flat, a little tiny hole wiped with tissue made it cave in very easily, awesome, not, so see this warning & if you buy 1 of these coolers & it isn't nice & flat possibly with 1 or more heat pipes bulging higher than the rest, get it exchanged & don't try to fix it yourself, it will cut you £60 to £70 short & leave you highly disappointed, could have pre ordered hitman absolution & assassins creed 3 with that & had change to buy I am alive, gutted.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-682.jpg

I did also check it out for how you remove the fans if you want to mod them which most modders would want to I expect, the plastic strip mounts the fans are on have some kind of arrow plugs 1 at the top & 1 at the bottom that go into the fins so there might be notches cut out of the fins so they clip in place, free them & you free the fans allowing you to mod them. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-683.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-684.jpg

Zalman you let me down with your garbage quality control on your flagship air cooler & I'm £65 out of pocket leaving me quite gutted indeed, that could have bought more aluminium or a bunch of good games, doubt I'll buy Zalman again, it did cross my mind to buy another because it does look awesome for an air cooler but could have had the same damn issue so thought I'd have to be very stupid to buy another because even if it was flat it would have been garbage surface finish on the base in need of a good lapping.

I have totally jumped ship & ordered a nicely engineered Noctua NH-D14 which I'll mod to be a monster of a triple custom 140mm Akasa viper fans which kick a hefty 110 CFM & are PWM fans :D that might well match OK water cooling, that's how I lose the plot, whatever failed me I make something far more awesome, I don't know why, I just do, maybe I need to get the gutted feeling away from me fast & this seems to work. :D


The workshop sort out can wait until the project is complete, this update wouldn't have been posted today if the Zalman cooler didn't show serious flaw & would have had the HTPC & stand altogether probably in a week or so, so see you in a week, at least I got what was going to be a special 4000th post done & I can comment on logs again, :) was just aiming to make it an excellent update, the full HTPC & stand & spindicator whirling away & sweet custom all aluminium fan, oh well, next update. :):up:

A bunch of the power section shots since I made the marble flush to the inset panel, I wonder if people will get sick of seeing this particular piece lol but if they do there is the anodising contrast thing to come & it will all need a very good sanding session before that, still looks a bit rough but I do like it, how bout you. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-685.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-686.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-687.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-688.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-689.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-690.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-691.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-692.jpg

More as soon as I have more to show. :)

[Fuganater]

Awesome work on the power button! I like the way you hooked all the negative leads together.

[msmrx57]

That switch is awesome!! :up: Can hardly wait to see it all lit up. Too bad about the cooler and the setback from it.

[d_stilgar]

That sucks with the CPU cooler. That's a lot of money to lose.

[Waynio]

Awesome work on the power button! I like the way you hooked all the negative leads together.
Thanks Fuganater :) was riekmaharg2 idea to do a copper ring, makes it a lot less cluttered from wires. :)
I'll hopefully have it up & running tomorrow so if I do I'll make a video & get some pictures of it.


That switch is awesome!! :up: Can hardly wait to see it all lit up. Too bad about the cooler and the setback from it.
Thanks msmrx57, hopefully tomorrow. :banana:
I got unlucky with the cooler but something better will happen now. 8)


That sucks with the CPU cooler. That's a lot of money to lose.
It is :( my fault though for thinking I could correct it instead of sending it back for a replacement, I could have stopped after I got it to a basic level of being flat but pushed too far to have a go at making it all flat, I'm sure it could still be used though after patching the holes up, it'll just be 2 3rds of the performance it should have been but I do have a hunch it will perform as good as one fresh out of the box & maybe even better with it being truly flat now but would have been sweet to see how good it would have been with no damaged heat pipes & a flat base.

[Waynio]

:D Narrowed down from 120 lol reason for a couple of shots of each angle is to show how the light is shifting around.

Liquid electrical tape, this stuff is straight from world of goo. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-693.jpg

Spindicator & all the assembly soldered together at last. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-694.jpg

I really should have used a fine brush instead of the big blompy one attached to the lid, the back of the housing ended up a heck of a mess but it's all insulated so I'm OK with that. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-695.jpg

It got worse lol.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-696.jpg

Moment of truth & the spindicator spins but 1 of the LED's doesn't seem to be working, 11 o clock no worky but because of the diffusion I can't tell. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-697.jpg

Testing all the coloured discs before mounting it in the case.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-698.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-699.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-700.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-701.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-702.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-703.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-704.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-705.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-706.jpg

Mounted & went with the light green disc.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-707.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-708.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-709.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-710.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-711.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-712.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-713.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-714.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-715.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-716.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-717.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-718.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-719.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-720.jpg

Some of the colours are just too powerful, yellow & dark green, what I think this needs is possibly a bit of tinting film adding to tone it down a touch possibly & instead of a 1mm acrylic padding disc I should replace it with an aluminium 1 with a pattern in it, maybe a very thin spiral, I'll do a few different ones, also bear in mind this is just nowhere near as good as it looks to the eye, in the dark there is a nice glow on the panels & the only way I can capture that is with the camera on a higher exposure which makes the marble look far too bright but the marble looks like how it does where the glow isn't captured but to the eye you see both nicely.


And a video, not good quality but it shows it a bit better than static images.
VUeds7gYoz0

[d_stilgar]

That first one makes the marble look as if it's on fire.

[Fuganater]

OMG that is so freaking sick!

[msmrx57]

:ovoh: droooooooooooooooooooooooooooooool.............. :bowdown:

[Waynio]

That first one makes the marble look as if it's on fire.
:D Hopefully the assembly won't start any when it's all together.


OMG that is so freaking sick!
:D Thanks Fuganater :up:


:ovoh: droooooooooooooooooooooooooooooool.............. :bowdown:
:D:up:

Made a couple more videos with different colours, the violet & blue aren't coming out right though on my kodak, the colours look weird.
bE6P9brd0dA
FcBGc9SHJdE

[Waynio]

A good productive evening, night & day.

I decided to tackle the stand, already printed the mounting points so just had to cut them from the sticker paper & carefully place in the right spots.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-721.jpg

Gone back to spot drilling since the new drill press is nice & love the table height adjustment, goes up & down by turning a crank but you do need to tighten it up so it's square but wow it is far better than my previous rock bottom budget bench drills.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-722.jpg

Also bought a cross vice at the same time as the drill press, it is extremely useful. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-723.jpg

Tapping.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-724.jpg

Mounting, I used 4 12mm m3 countersunk screws on both sides.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-725.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-726.jpg

More guide templates which I had to redesign because I had no 3mm 20mm flat bar & only 6mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-727.jpg

The depth setting on the drill press, I'd have probably screwed up without it.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-728.jpg

To keep fixings hidden I decided to file angles that the flat bars fit on to.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-729.jpg

These are the flat bars but didn't take any pictures of the filing process but I had to make them match the angles on the big panels.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-730.jpg

And extra support added.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-731.jpg

Few shots before I get on with the HTPC. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-732.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-733.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-734.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-735.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-736.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-737.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-738.jpg

Need a rest now but I am on a mission to get this completed before December, want to play Hitman & assassins creed 3 on this rig. :D

[blueonblack]

That is a beautiful chunk of metal right there! I could never tackle that. +rep for the progress!

[Stonerboy779]

That is a drool worthy drill press.... oh and the build is coming along nicely too ;)

[modscases.com]

awesome job man this should be heavy :)

[Waynio]

That is a beautiful chunk of metal right there! I could never tackle that. +rep for the progress!
Thanks blue, I don't know if I could again :D I think 2013 I might take the year off modding or at least modding like this, could do with some lighter projects, been a bit of an endurance test this one. :D:up:


That is a drool worthy drill press.... oh and the build is coming along nicely too ;)
It's a nice one, my other bench ones wouldn't have been able to drill the tops of those panels without making up a makeshift precarious table lol.
Cheers Stonerboy779. :)


awesome job man this should be heavy :)
:D Yeah the weight is building up now it's coming together :eek::) the diet I'll put it on later should help though. :up:
Thanks modscases. :)

I hadn't got around to fixing the bottom nose plates to the feet all this time so finally got that sorted, they were just placed there all along until now. :D

I used 5mm aluminium rod cut into 3 25mm pieces & pushed them through the nose & also drilled the plates so they would slide on & for fixing to the legs I drilled & countersunk 3mm holes through the 10mm panel hidden by the side arch panels & for placing a marker on where to drill I held it all in place how it should be, placed a 3mm drill bit through the hole & gave the bit a tap with a chunk of metal which gave perfect position, then 2.5mm drilled the plates, tapped & screwed in place with 12mm countersunk screws.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-739.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-740.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-741.jpg

The shoes & stand is now complete except cleaning up any rough bits & surface finishing but all that can wait until everything is together because it's the 2nd to last step before taking to the anodisers.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-742.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-743.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-744.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-745.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-746.jpg

So sorry about leaving you to expect HTPC progress this time but had to get those plates fixed on & they were a bit tricky to do right. :D

HTPC is definitely up next though now. :)

[BS Mods]

Looks so awesome! Your mods force me to sit and stare for a while so I can take it all in. It's like looking at art.

[SXRguyinMA]

:bowdown:

that's about all I can say :D

[Waynio]

Looks so awesome! Your mods force me to sit and stare for a while so I can take it all in. It's like looking at art.
:D Thanks BS, going to be fun photographing the completed project. :D:up:


:bowdown:

that's about all I can say :D
:D Thanks SXRguyinMA :up:

I changed the optical cover to use a 10mm plate for a cleaner look.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-747.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-748.jpg

Making the edges perfectly flat by filing & using the disc sander.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-749.jpg

Applied the top & bottom templates.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-750.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-751.jpg

Drilling nearly all the way through the optical plate leaving about 2mm as an alternative mounting point since I changed the design slightly.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-752.jpg

Had lots of tapping to do in this session.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-753.jpg

This is a sweet method for drilling exactly where you want to, 3mm hole, 3mm drill bit, give it a tap with something & it leaves a nice mark for drilling, just as good as drilling through a stack of panels.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-754.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-755.jpg

Here is the 6mm hole I drilled which leads to 2mm depth 3mm hole for alternative mount point.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-756.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-757.jpg

In place.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-758.jpg

Fixed in square bars & round bars, used m3 grub screws in the round bar that go straight through the panel & into the square bars & then marked & drilled countersunk holes to fix the round bars.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-759.jpg

Cut some 10mm round bar with hack saw, made the ends perfectly flat on the disc sander, drilled, tapped & added grub screws so they go through the panel & into the optical plate.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-760.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-761.jpg

I called it a wrap at this point, think I started at about midnight & finished up around 4PM, was knackered. :D

It's been extra difficult with the design having 3/8" for the 10mm plate, it's a tight design so that tiny difference makes quite a difference on most of these bits I've been doing & I really should have tweaked the design as soon as I realised this when I got the materials but didn't so have had quite a bit of messing to make it all work still but once this HTPC is done everything else should be more straight forward, I've not been fully tuned in with doing this lately, I just got to go at it like I did last night but much more regular if I want this complete before December. :)

[Fuganater]

So awesome to see this coming together.

[jdbnsn]

This case is going to go down in history as one of the most incredible scratch built cases. Awe-inspiring my friend!

[Waynio]

So awesome to see this coming together.
Thanks Fuganater, had a little time out again but I intend to do normal sized session from now but every day so think things will come together faster now. :):up:


This case is going to go down in history as one of the most incredible scratch built cases. Awe-inspiring my friend!
:D Thanks jd :eek::up::banana:

No step by step photos this time, this is some progress from yesterday & today, been trying to get back into making this come together but nothing new was done that you haven't seen already, drilling, tapping, heating brass inserts into the IO piece to fix to the sliding mobo tray, everything shown here now though is fully fixed together & it's nice & solid, :D alignment of the triple layer mobo tray holding pieces was off a tiny bit also which needed some filing so there aren't any steps you can feel, tiny problem of it looking slightly off now so I'll do something to make it look better than intended. :D

Already started on removing the steps but some can be seen still here.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-762.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-763.jpg

After that they aren't steps but just surface differences in need of further finishing.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-764.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-765.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-766.jpg

I could do with buying a detail power sander for doing all the outside edges as soon as I can, filing will be too iffy with it all being cut to the line, bit of power sanding will speed things up a little without taking too much off. :D

I'm stopping doing massive sessions & will instead just do a session every day, started this project with that in mind but didn't take long for me to start burning myself out by not pacing myself properly.

I paid for a 2 year photobucket sub so changed my settings to what I re-size my images to when taken off the camera but think I'll make future ones a little smaller than this & reserve bigger res for final shots of things.

[Fuganater]

Woot for frequent updates!

[Waynio]

Woot for frequent updates!

:D I missed yesterday :redface: but it was a busy day AFK.

OK, the HDD rack alternative version, earlier box version was missing a 5th slot unfortunately so I screwed that one up, this one isn't a box one & instead a plate with added slot pieces that fix to the aluminium above & below & has fixing plates for 4 HDD & 1 SSD. :D

Decided to use the 3mm brown tint acrylic.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-767.jpg

Freshly cut.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-768.jpg

Sanded to the lines.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-769.jpg

Bunch of bits.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-770.jpg

Drilling the fixing plates now so I don't drill in the wrong spots later.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-771.jpg

The fan perch v2 it should fit perfectly to the custom fan when I get them made.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-772.jpg

Because of how well the IO pieces worked out I decided I'll do that technique of using a template on 1 of the pieces, draw & cut around the extras & stick them together fully before cutting the pattern for layered pieces of acrylic from now on, I'll just have to go on the slowest cut speed so it isn't as prone to melting.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-773.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-774.jpg

Here are the acrylic parts waiting to be glued together, might do this before I go bed.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-775.jpg

4 HDD & 1 SSD tray.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-776.jpg

Cut.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-777.jpg

Sanded & drilled & countersunk.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-778.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-779.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-780.jpg

End of latest session. :)

Looks like I should reduce picture size a little more, I'll try 900 as the biggest dimension next. :up:

[Waynio]

42 days left if including today, need to push harder. :D

Micro update but it's an update.

I cut 4 little pieces of the same aluminium I used for the hdd trays to make spacers for while I stick them together, the adhesive does it's initial setting fairly quick so I managed OK with just 4 pieces to do the spacing, would have been easier with 6 more but I didn't fancy cutting more, I need a new band saw blade, current ones are well past useful & was not nice at all to cut with.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-781.jpg

Upper & lower hdd slide rack.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-782.jpg

Fan perch stuck together, weighted down & is almost 20mm thick, I'll cut the shape, slim it down to 19mm & on next session get these parts mounted.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-783.jpg

42 days sounds like a fair bit of time but it soon comes & goes especially if you goof off playing games & have some AFK to slow you down. :D

Tweaked my camera sharpness & contrast settings a little too & picked up some good photography tips from Paul Tan but none of the lighting tips will be used until I'm past the main workshop stuff.

[Waynio]

40 days left since it's just crept past midnight. :D

OK the HDD slide panels have cured for a while, you can see here the holes that need completing.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-784.jpg

Completing the holes.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-785.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-786.jpg

Then I had to dismantle some of the HTPC to get to the level on top of the optical section for adding a few mounting holes.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-787.jpg

Was tricky to align this template spot on, new holes & the ones the drill bit is pointing at was tapped, all the rest was countersunk.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-788.jpg

Back to the acrylic & placed brass inserts in the holes.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-789.jpg

Pressed in with soldering iron.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-790.jpg

Reassembled & had to take about 2mm off the width of all the HDD trays so they would fit in, I also mounted spare HDD's & an SSD to them to see how it looks.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-791.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-792.jpg

Full.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-793.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-794.jpg

I'll do more today after a sleep & some food. :D

[Fuganater]

Thats nice!

[jdbnsn]

I love your style!

[Waynio]

Thats nice!
Thanks Fuga :up: they slide in/out nicely. :)


I love your style!
:D:up: Thanks jd :)

HTPC Fan perch 20mm 4 5mm layers glued together.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-795.jpg

Basic first cuts.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-796.jpg

Used the modded band saw blade but it was causing it to melt when doing the smaller curve cuts, the blade got completely stuck in there.
Had to saw to the blade & file to the blade to free it, those curves are ones that will be visible too so I had a big drum sanding session to clean them up, was a PITA. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-797.jpg

Used a sturdy fret saw blade for doing the bigger curve & did it very slow going forward 3 millimetres & going back about 6 over & over & it prevented it from melting, also did that on half speed instead of the slowest, worked a lot better. :)
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-798.jpg

Installed brass inserts to the fan perch.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-799.jpg

Filed the optical plate to represent where I need to round the corners.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-800.jpg

Used the hack saw to cut down 7mm so its down to 3mm.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-801.jpg

Put it in the cross vice & set it up to drill down so 3mm would be left to make filing a little easier.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-802.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-803.jpg

My arms got Popeyed ugugugugug. :D
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-804.jpg

Aluminium shortbread.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-805.jpg

I filed down far enough to let me finish it off with a mill bit in the drill press & cross vice, it worked quite nicely really.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-806.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-807.jpg

Smoothed things off more with a file.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-808.jpg

Cut the optical tray out.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-809.jpg

Installed.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-810.jpg

Optical plate & fan perch installed.
http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-811.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-812.jpg

http://i433.photobucket.com/albums/qq59/waynio_2008/Lean%20and%20Green%20%20%20%20Scratch%20built%20du al%20PC%20project/LAG-813.jpg

That turned out to be a big session but was one of those where I just wouldn't call it a day until I got what I intended to do done, I'll make my next session a small one to balance things out again. :D

[Fuganater]

Drive bay will be nice but I think you should have went with a slot load. Would have look much cleaner for this build.

[Waynio]

Drive bay will be nice but I think you should have went with a slot load. Would have look much cleaner for this build.

Know what you mean but I prefer full speed optical when I need to use optical but not aesthetically but I'd rather have the good function & cheaper price full size gives :) some thought the optical on stealthlow was a slim one & some didn’t even know it was an optical drive until I pressed eject, plus I've not designed the tray cover for this one yet. :D

Was going to switch from optical media to HDD’s for backing my media collection up & use a good external optical drive whenever I need one but just as I was going to the floods hit the HDD factory & the prices shot up crazily high & I wasn’t willing to pay that much for something that is no different than normal HDD’s, prices have come down but still not as awesomely cheap as they were & they have shorter warranty's now also but I will try to cram in 4 3TB HDD's into the HTPC as the final storage but my current drives will do until I raise the money for them. :D

For an SSD on the gaming rig I'm unsure about putting the latest firmware for the corsair force 3, it was driving me mad with completely random BSOD's & it happened when I was almost done on a new design & knackered my OS but thanks to Linux on a usb flash drive I managed to salvage a good chunk of it so because of that I highly value stability on SSD's more than speed, Samsung 830s look great to me, I know they have released 840 series but they are more expensive & have slower writes. :)

I'll have a go at doing the first custom fan next. :up:

[Fuganater]

I'm still all about the Curcial M4 series. I have several 128GB ones and I'm thinking about getting 1 or 2 256/512GB ones.

[Waynio]

I'm still all about the Curcial M4 series. I have several 128GB ones and I'm thinking about getting 1 or 2 256/512GB ones.

Good drives from what I hear or read rather. :D:up:

[Beta-brain]

Great work, your devotion and patience on that scroll saw deserves a medal :bowdown: +rep