Project: Heavy Metal

[JRSCAcura]

Hey everyone
This is my first post and incidentally my first time modding anything on a computer :eek: .
I got bored with my stock Dell XPS 600 so I made the decison to face lift it. My project being called heavy metal refers to idea of making as much of the plastic into metal as possible.

stock
http://img17.imagevenue.com/loc482/th_81531_DSC02518_122_482lo.JPG (http://img17.imagevenue.com/img.php?loc=loc482&image=81531_DSC02518_122_482lo.JPG)

Top
http://img151.imagevenue.com/loc585/th_81543_DSC02519_122_585lo.JPG (http://img151.imagevenue.com/img.php?loc=loc585&image=81543_DSC02519_122_585lo.JPG)

Side
http://img22.imagevenue.com/loc447/th_81551_DSC02520_122_447lo.JPG (http://img22.imagevenue.com/img.php?loc=loc447&image=81551_DSC02520_122_447lo.JPG)

front open
http://img157.imagevenue.com/loc325/th_81558_DSC02521_122_325lo.JPG (http://img157.imagevenue.com/img.php?loc=loc325&image=81558_DSC02521_122_325lo.JPG)

Inside
http://img168.imagevenue.com/loc600/th_81528_DSC02516_122_600lo.JPG (http://img168.imagevenue.com/img.php?loc=loc600&image=81528_DSC02516_122_600lo.JPG)

[JRSCAcura]

well time to get crackin on it. Tore the guts out of it so I could chop it up.

http://img163.imagevenue.com/loc540/th_81564_DSC02522_122_540lo.JPG (http://img163.imagevenue.com/img.php?loc=loc540&image=81564_DSC02522_122_540lo.JPG)

Than chopped the top mesh out of the case for where I'm putting a 120mm fan
http://img168.imagevenue.com/loc359/th_81570_DSC02523_122_359lo.JPG (http://img168.imagevenue.com/img.php?loc=loc359&image=81570_DSC02523_122_359lo.JPG)

Next the side had to go, so you can see all the crazy insides lol
http://img166.imagevenue.com/loc317/th_81572_DSC02524_122_317lo.JPG (http://img166.imagevenue.com/img.php?loc=loc317&image=81572_DSC02524_122_317lo.JPG)

http://img120.imagevenue.com/loc493/th_81579_DSC02525_122_493lo.JPG (http://img120.imagevenue.com/img.php?loc=loc493&image=81579_DSC02525_122_493lo.JPG)

[Mitternacht]

Welcome to TBCS!

Well, heavy metal, huh? Cool, I'm a mealhead, too. What metal band inspires you the most? Or do you like them all in general? I'd do my case after Metallica if I would take a metal theme. Also, if I were you, I'd try to get rid of all that green plastic inside.

[ESX]

Omg yuck green :/

So anyways, whats the overall theme?

[JRSCAcura]

well I do like a bunch of heavy metal but this title refers more to the materials I'm using in this project trying to use mostly metal and lose the plastic where possible.

[sirkillalot617]

Welcome to tbcs also i kinda like metal music but bit lighter such as avenged sevenfold

[Mitternacht]

Welcome to tbcs also i kinda like metal music but bit lighter such as avenged sevenfold

breaking benjamin ftw

[JRSCAcura]

time for change. I wiped the whole case down with silicon, wax and grease remover, than sprayed it all with self etching metal primer, I found some pretty cool paint from krylon that is a metallic black paint, it has metal bits in it and dries to a textured finish, so on that went, turned out great has a black base with raised silver specks in it.

http://img167.imagevenue.com/loc373/th_82646_DSC02526_122_373lo.JPG (http://img167.imagevenue.com/img.php?loc=loc373&image=82646_DSC02526_122_373lo.JPG)

Close up
http://img24.imagevenue.com/loc575/th_82649_DSC02527_122_575lo.JPG (http://img24.imagevenue.com/img.php?loc=loc575&image=82649_DSC02527_122_575lo.JPG)

[sirkillalot617]

breaking benjamin ftw
mmm got a friend who likes that im guessin u like stuff like in flames and maybe 3 doors down

[JRSCAcura]

putting it back together so I can post hahaha. Don't you love all the green plastic crap?

http://img16.imagevenue.com/loc567/th_82662_DSC02529_122_567lo.JPG (http://img16.imagevenue.com/img.php?loc=loc567&image=82662_DSC02529_122_567lo.JPG)

[sirkillalot617]

delll really should get rid of the green it makes there systems look cheap

[JRSCAcura]

The PSU on this case is mounted underneath so the case is sitting on it. Well I thought it would look pretty cool being able to see inside the PSU from the top while looking into the case, I had to cut the top off the PSU, than the one side of the case because it swings open, finally the other side of the case (the door).
I put a black light in the PSU which shines up into the casebut you can't see the actual tube. I'll take pictures of it when I pull the case apart again to show the custom aluminum mount I made for it. I also installed 2 red led light bars top and bottom in the case. Don't mind the wires I haven't gotten close to that yet.

http://img37.imagevenue.com/loc592/th_68193_DSC02549_122_592lo.JPG (http://img37.imagevenue.com/img.php?loc=loc592&image=68193_DSC02549_122_592lo.JPG)

[JRSCAcura]

ok on to the good stuff. Time to make the new case for heavy metal. Couldn't cheap out here so I used 18 gauge thick 304 stainless steel to make the case on both sides and the top. here are the results. I made the window side wrap around the back 1 1/2" to cover a gap where the stock door plastic fit and locked the case closed, all the edges are hemmed over (folded over on themselves and pressed flat) to make the edges nice and smooth and look a little heavier. than the corners are welded to make the slight open edge dissapear, you have the cut part of the corner off before hemming so it doesn't fold over on itself. Than the corners are ground flush and finished. I was having a hard time coming up with an idea for the window on the case untill I saw the green lee punches. I punched all the holes out than flared them outwards and swirled the stainless with a 90 degree die grinder with a scotchbrite disc on it.
the sides and top are just sitting on the case for now I haven't made the window or bolted the side and top on yet.

http://img127.imagevenue.com/loc581/th_68201_DSC02553_122_581lo.JPG (http://img127.imagevenue.com/img.php?loc=loc581&image=68201_DSC02553_122_581lo.JPG)

close up
http://img103.imagevenue.com/loc575/th_68208_DSC02557_122_575lo.JPG (http://img103.imagevenue.com/img.php?loc=loc575&image=68208_DSC02557_122_575lo.JPG)

[JRSCAcura]

In this first pic you can see the open corner that haven't welded yet on the top corner gives you an idea of how the edges are hemmed. Without the cases panels being bolted on they are misaligned a bit but no worries once they get bolted down they will line up perfectly. I need to cut the lexan side window next and the PSU acrlyic (ordering some uv red) and drill the case, than install rivnuts to hold everything on with 1/4" 20 stainless button head bolts.

http://img158.imagevenue.com/loc533/th_68215_DSC02554_122_533lo.JPG (http://img158.imagevenue.com/img.php?loc=loc533&image=68215_DSC02554_122_533lo.JPG)

In the Dark

http://img158.imagevenue.com/loc465/th_68224_DSC02565_122_465lo.JPG (http://img158.imagevenue.com/img.php?loc=loc465&image=68224_DSC02565_122_465lo.JPG)

[M!ST!CX]

so far its very nice

[jdbnsn]

Looking pretty cool so far, love the stainless steel but the colors still look a little busy. I got excited when I saw Heavy Metal thinking you were modding a theme based on the animated movie but this looks good too! Welcome to the forums!

[JRSCAcura]

Thanks for the welcome and words of encouragment. Well the colours are going to be toned right down to basically just stainless steel, Aluminum, copper for sure and possibly some brass. All of the green plastic is going away and the stock heat sink on the CPU is going as well with a zalman 9500 in it's place, than all of the wiring is getting done. Hoping for it to look nice and simple and clean. A quick question for a newb, how do I power add ons like fans and lights without just cliping into the 4 pin power connectors piggyback style (which looks like crap)? All the fan connections that the dell is running are a 4 wire small stlye connectore that clips right onto the mobo, and on start up the screen says it detects the stock fans aren't working since they are removed with new fans just running straight PSU power.

[Commando]

Looks killer.

[|wm|]

This is going very well. Good work and can't wait to see how this turns out. The stainless panel is really nice. Hope I don't overstep my bounds here, but have you considered melting the acrylic through those circular holes on the panel? Basically just take your acrylic panel, throw it on top of the stainless panel, and stick in the oven on some risers. Bake at 320 for about 10 and it should start to bubble through the holes giving them a convex bubble look. If it doesn't drape on its own, just press in with a large diameter ball. That maybe nothing like what you're after, but it was the first thing I though of then I saw the way your pressed out the edge of the circles.

Keep it up, and good job on the de-Dell-ification.

[jdbnsn]

As for the fans, there are tons of way you can creatively wire them into your design that will add to the overall look of the project. I always link to this guy's worklog because I particularly like his solution, skim through and see what he did.

http://www.thebestcasescenario.com/forum/showthread.php?t=2077&highlight=metropolis

[JRSCAcura]

This is going very well. Good work and can't wait to see how this turns out. The stainless panel is really nice. Hope I don't overstep my bounds here, but have you considered melting the acrylic through those circular holes on the panel? Basically just take your acrylic panel, throw it on top of the stainless panel, and stick in the oven on some risers. Bake at 320 for about 10 and it should start to bubble through the holes giving them a convex bubble look. If it doesn't drape on its own, just press in with a large diameter ball. That maybe nothing like what you're after, but it was the first thing I though of then I saw the way your pressed out the edge of the circles.

Keep it up, and good job on the de-Dell-ification.


Awww your stealing my thunder here man hahaha . Yeah I'm planning on bublling the lexan window through the holes, I'll try the oven method and if it doesn't work than I'll build a vaccuum box for it and do it that way. Thanks for the wiring link was thinking something along those lines. Well I'll be working on it this week so stay tuned for more updates.

[simon275]

Good to see a dell go under the knife.

Nice concept with all the holes. One thing though lots of dust will get into your case so make sure you clean it out or keep it in a dust free environment.

[Luke122]

I love that black finish you got on the inside.. I think I'm going to do that on my Karma mod.

Both of my PC's are un-dell'd. Including the majority of the components in Karma.

[JRSCAcura]

Well I got all set to put the window in the oven to make it bulge through the side panel. One problem my oven is about 2 inches to small depth wise to fit the whole thing in:dead: . So unless I can find a bigger oven it's gonna stay flat for now lol. the window side has the lexan cut and I'm going to be cutting the fan mount for my 120mm in the top of the case today at work. I'll have some pictures of it all tonight when I get home from work. need to order a fan controller and do some wiring soon.

[Airbozo]

Well I got all set to put the window in the oven to make it bulge through the side panel. One problem my oven is about 2 inches to small depth wise to fit the whole thing in:dead: . So unless I can find a bigger oven it's gonna stay flat for now lol. the window side has the lexan cut and I'm going to be cutting the fan mount for my 120mm in the top of the case today at work. I'll have some pictures of it all tonight when I get home from work. need to order a fan controller and do some wiring soon.

Move the rack as far to the top as you can and then just let the door stay ajar. You should still get enough heat to melt it... Worked for me, but I was making Soufflé's... (and they are touchy with heat).

[Airbozo]

Looking pretty cool so far, love the stainless steel but the colors still look a little busy. I got excited when I saw Heavy Metal thinking you were modding a theme based on the animated movie but this looks good too! Welcome to the forums!

I also thought this might be dedicated to the movie or magazine. With so much content in both the movie and magazines, choosing a theme would still be a chore.

BTW: I have been collecting Heavy Metal magazine since 1976. I have 2 copies of the first issue, one medium quality (for reading) and one pristine, never been opened. I am missing about 8 issues...

http://www.metaltv.com/

[JRSCAcura]

Worked for me, but I was making Soufflé's... (and they are touchy with heat).

HAHAHA Too funny. Not enough room in there even like that. So I went and bought a much thinner sheet of acrylic which should work better that lexan since lexan will draw moisture in and bubble when heated. I'm gonna try it with the wifes hair dryer lol.
http://img18.imagevenue.com/loc458/th_88229_DSC02578_122_458lo.JPG (http://img18.imagevenue.com/img.php?loc=loc458&image=88229_DSC02578_122_458lo.JPG)


Well I cut my lexan window out and I used some pretty thick stuff I had laying around that was 1/4".
http://img152.imagevenue.com/loc308/th_88187_DSC02567_122_308lo.JPG (http://img152.imagevenue.com/img.php?loc=loc308&image=88187_DSC02567_122_308lo.JPG)

Got all ready to put it in the oven and it didn't fit. So for now I have a flat window in the case.
http://img163.imagevenue.com/loc493/th_88217_DSC02570_122_493lo.JPG (http://img163.imagevenue.com/img.php?loc=loc493&image=88217_DSC02570_122_493lo.JPG)

In other news I cut the hole in the top of the stainless case today for my 120mm fan that blows right down on the heat sink for the CPU. Since I didn't have a punch near that big I used a nibbler and a die grinder with a few cutters/sanders to make the hole and finish it out nice. Just need to drill the holes for the fan now and mount it.
http://img164.imagevenue.com/loc457/th_88236_DSC02572_122_457lo.JPG (http://img164.imagevenue.com/img.php?loc=loc457&image=88236_DSC02572_122_457lo.JPG)
http://img143.imagevenue.com/loc394/th_88254_DSC02574_122_394lo.JPG (http://img143.imagevenue.com/img.php?loc=loc394&image=88254_DSC02574_122_394lo.JPG)
http://img44.imagevenue.com/loc454/th_88243_DSC02573_122_454lo.JPG (http://img44.imagevenue.com/img.php?loc=loc454&image=88243_DSC02573_122_454lo.JPG)

I ordered a cable sleeveing kit, dual CCL UV lights, and a fan controller today so I should see those soon, also my uv red acrlyic came today so I can start with that.

I picked up some rounded IDE cables for my dvd drives but when I hooked it up and started the computer I got a black screen saying that the slave drive couldn't be found and than it went to the windows opening screen and froze? I'm stumped since all I did was change the cable, if anyone knows what it is please let me know.
http://img166.imagevenue.com/loc464/th_88262_DSC02575_122_464lo.JPG (http://img166.imagevenue.com/img.php?loc=loc464&image=88262_DSC02575_122_464lo.JPG)
http://img21.imagevenue.com/loc409/th_88269_DSC02576_122_409lo.JPG (http://img21.imagevenue.com/img.php?loc=loc409&image=88269_DSC02576_122_409lo.JPG)
http://img175.imagevenue.com/loc320/th_89340_DSC02577_122_320lo.JPG (http://img175.imagevenue.com/img.php?loc=loc320&image=89340_DSC02577_122_320lo.JPG)

[Airbozo]

May have to set the master slave jumpers with that cable. The one I picked up a couple of months ago had the same effect on my system, but I was plugging in 2 dvd drives and it could not see one. Check the jumpers and try again.

[JRSCAcura]

ok figured out the jumpers and now it works perfectly. Thank you

[simon275]

Nice case good work with the blow hole.

Nice case fan.

[|wm|]

drag about the oven size. +e for effort. keep going man, good work.

[JRSCAcura]

Good things happened today. The brown truck came to work with gifts for me. I got my fan controller (which will really help clean up my wiring) my ccfl UV's and my wiring loom kit.
http://img160.imagevenue.com/loc437/th_55236_DSC02587_122_437lo.JPG (http://img160.imagevenue.com/img.php?loc=loc437&image=55236_DSC02587_122_437lo.JPG)

http://img169.imagevenue.com/loc502/th_55243_DSC02588_122_502lo.JPG (http://img169.imagevenue.com/img.php?loc=loc502&image=55243_DSC02588_122_502lo.JPG)

Being inspired by the new hardware I finally remembered to bring home my tinsnips and heat gun. How should I go about bending my acrylic for a nice 90 degree bend. I don't have a fancy line style heater sitting around.

[JRSCAcura]

also drilled the holes for my 120mm case fan and test fit it. Need to trim the top of the case/cage a hair more to fit right.
http://img172.imagevenue.com/loc343/th_55211_DSC02579_122_343lo.JPG (http://img172.imagevenue.com/img.php?loc=loc343&image=55211_DSC02579_122_343lo.JPG)

welded the corners on the top/backside of the case and quickly finished them out still need to sand the whole case for brushed look.
http://img28.imagevenue.com/loc500/th_55220_DSC02581_122_500lo.JPG (http://img28.imagevenue.com/img.php?loc=loc500&image=55220_DSC02581_122_500lo.JPG)

http://img136.imagevenue.com/loc359/th_55213_DSC02580_122_359lo.JPG (http://img136.imagevenue.com/img.php?loc=loc359&image=55213_DSC02580_122_359lo.JPG)

and a pic of my copper sheet and red acrylic
http://img144.imagevenue.com/loc335/th_55229_DSC02582_122_335lo.JPG (http://img144.imagevenue.com/img.php?loc=loc335&image=55229_DSC02582_122_335lo.JPG)

[JRSCAcura]

ok not trying to get off topic here but in case anyone is interested I'm a welder/fabricator. Thought I would post up some of the other stuff I do.

49 pick up with full air ride technologies and custom front clip and suspension
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjAzNDZzNDEzZGZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjAzNTZzNDEzZGZkMzF5NTQx.jpg
48 anglia about to get whole front redone
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjAzNjZzNDEzZGZkMzF5NTQx.jpg
with the front end redone
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjA1MDZzNDEzZGZkMzF5NTQx.jpg
60's front engine dragster aluminum gas tank
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjAzNzZzNDEzZGZkMzF5NTQx.jpg
english wheel I made ( wheel set is on the other side)
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjAzODZzNDEzZGZkMzF5NTQx.jpg
63 nova convertible with an LS2 crate engine and air ride technologies setup custom made entire suspension setup and all car mods
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjAzOTZzNDEzZGZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjA0MDZzNDEzZGZkMzF5NTQx.jpg
03 subaru WRX built for targa newfoundland rally race
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjA0MzZzNDEzZGZkMzF5NTQx.jpg
same car after crashing and being rebuilt with STI driveline and painted also lexan windows and wing roof scoop ect
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjA0MjZzNDEzZGZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/wetoddimage.wtdr/wMTMzMjA0MTZzNDEzZGZkMzF5NTQx.jpg

[tybrenis]

You're links are broken, try using the image button on the toolbar: http://www.thebestcasescenario.com/forum/images/editor/insertimage.gif :D

Anyways, this case is looking great so far! If you wanted to bubble out the window, I think that would be really cool. However, I don't recomend doing it with Lexan, as polycarbonate (Lexan) has a much higher moisture content than acrylic and it will bubble under heat unless treated very carefully and even pre-dried.

I think the red acrylic would look pretty cool bubbled out through those holes. You can do it in your oven as suggested, just make sure to keep it cracked and watch it the whole time, as that can be very dangerous.

I just finished building my home made vacuum former, and having a bit of experience with that, I can tell you it will probably be easier to just do the oven idea, as with a vacuum former you'd have to make a positive mold of the exact sized bubble etc. and in general it'd just be a pain in the ass.

Best of luck to you! This is looking good.

[JRSCAcura]

Thanks for the encouragment, definetly helping me to keep going. I already ditched the lexan for some much thinner acrylic, going to try to get it to drop through with a heat gun :think: . I wanted to use the red acrylic but the peices I got are 12"x12" and the window in the case needs to be 16"x16". I'm still stuck on how to bend my red acrylic to make the PSU cover thought any advice on an effective way of doing that?

[JRSCAcura]

Ok I just did a test peice of acrylic trying to bubble it through the holes on the side of the case with a heat gun. First I tried to let the acrylic drop through on it's own but it had to get to hot in order to do so and started to bubble the acrylic. Next I heated the acrylic till it was starting to raise up from getting hot on one side than put my shop vac on the other side to pull it through the stainless, and drum roll please SUCCESSso I'm going to try the whole side now using this method, although I need to make some adaptors for the vacuum to work on the bigger holes in the center.

[Airbozo]

...than put my shop vac on the other side to pull it through the stainless, and drum roll please SUCCESSso I'm going to try the whole side now using this method, although I need to make some adaptors for the vacuum to work on the bigger holes in the center.

BRILLIANT!

Next to duct tape, shop vacs rate up there in most versatile tools!

[tybrenis]

Nice, good job!

For line bending acrylic, I built myself a nichrome wire bender. If you have 20 minutes and 20 bucks I'll show you how to build one, ask if you're interested. I think I still have some wire you could use, too. That's the professional way.

The sketchy way (and I mean sketchy) is to use a heat bender and bend the acrylic over a desk corner or similar. I'm not so sure it's precise enough for your purposes.

[slytherock]

For line bending acrylic, I built myself a nichrome wire bender. If you have 20 minutes and 20 bucks I'll show you how to build one, ask if you're interested. I think I still have some wire you could use, too. That's the professional way.

Dont know avout him, but I'm really inerested in knowing how. maybe a little tutorial?

[JRSCAcura]

very interested if you could show me how to make the bender for acrylic. I'd appreciate the how to very much, and you can never had to many tools.

[JRSCAcura]

Since I've disconnected the original dell fans from the mobo I'm getting this message now when I startup the system (see picture below). What do I need to change to get rid of that?
http://img136.imagevenue.com/loc454/th_46029_DSC02589_122_454lo.JPG (http://img136.imagevenue.com/img.php?loc=loc454&image=46029_DSC02589_122_454lo.JPG)

The mess of wires was driving me nuts so I took some time and loomed a few cables. I still need to wait and do the HDD's and a few fan and power cables when the case comes apart. So far though it's made a big difference.

http://img134.imagevenue.com/loc423/th_46043_DSC02591_122_423lo.JPG (http://img134.imagevenue.com/img.php?loc=loc423&image=46043_DSC02591_122_423lo.JPG)

http://img175.imagevenue.com/loc551/th_46070_DSC02595_122_551lo.JPG (http://img175.imagevenue.com/img.php?loc=loc551&image=46070_DSC02595_122_551lo.JPG)

I had one ribbon cable that was smaller than a floppy ribbon and I didn't know what kind it was so I couldn't order a rounded replacement. What to do? Make my own thats what. This cable runs up to the power on button and usb stuff at the front of the case, thank god it's cleaned up now.

http://img23.imagevenue.com/loc510/th_46036_DSC02590_122_510lo.JPG (http://img23.imagevenue.com/img.php?loc=loc510&image=46036_DSC02590_122_510lo.JPG)

http://img34.imagevenue.com/loc436/th_46051_DSC02593_122_436lo.JPG (http://img34.imagevenue.com/img.php?loc=loc436&image=46051_DSC02593_122_436lo.JPG)

http://img41.imagevenue.com/loc476/th_46063_DSC02594_122_476lo.JPG (http://img41.imagevenue.com/img.php?loc=loc476&image=46063_DSC02594_122_476lo.JPG)



One last thing that I'm pretty excited about is the security camera I'm going to be using for my house. The camera body is solid aluminum, indoor/outdoor night vision, all the good stuff. It's going infront of my garage door to monitor the front area of the house and front door. The bottom card in the PCI slots is my 4 channel camera card.

http://img164.imagevenue.com/loc331/th_46073_DSC02596_122_331lo.JPG (http://img164.imagevenue.com/img.php?loc=loc331&image=46073_DSC02596_122_331lo.JPG)

[tybrenis]

Hey guys,

Thought I'd share a bit about my heat benders.

The idea is very simple. Basically, you have a nichrome wire strung horizontally. The wire is put under tension using springs to stop from sagging when it heats up. Heating the wire is as simple as applying the proper voltage across the wire.

First, you will need a length of nichrome wire and some aluminum channel. Then, you will need a spring, some scrap metal, two bolts, and some wing nuts.

The nichrome wire attaches to one end of the bolt on each side. Then, a spring is used to put the wire under tension. The process is simple - first, you tighten down the spring so it is completely compressed. Then, you attach your nichrome wire. Then, you unsrew your wing nut so the spring expands, putting tension on the wire. These pics will help:

http://www.powerpackedpc.com/images/tbcs/heat_bendert1.jpg
http://www.powerpackedpc.com/images/tbcs/heat_bendert2.jpg
http://www.powerpackedpc.com/images/tbcs/heat_bendert3.jpg

Shameless plug: I actually offer these for sale if anyone is interested, I build complete units to your specs. PM me if interested.

[GT40_GearHead]

nice cctv camera you got there how much $$$???

[JRSCAcura]

nice cctv camera you got there how much $$$???

My friend does security for his families company and ordered a bunch from china. I got a killer deal from him on the camera $60. It honestly weighs a good 3 pounds very nice. The night vision is wicked on it too, can't tell it's even in the dark it's that good.

[JRSCAcura]

the acrylic bender is very nice. What are you using to control the voltage going into the wire?

[xmastree]

Since I've disconnected the original dell fans from the mobo I'm getting this message now when I startup the system (see picture below). What do I need to change to get rid of that?
http://img136.imagevenue.com/loc454/th_46029_DSC02589_122_454lo.JPG (http://img136.imagevenue.com/img.php?loc=loc454&image=46029_DSC02589_122_454lo.JPG)

go into the BIOS (F2), there will be a setting there somewhere about halt on errors. Set it to none.

Probably... :rolleyes:

[JRSCAcura]

Probably... :rolleyes:

:D

cool thanks I'll try it

so I cut my new window out of the acrylic sheet, drilled the holes to attach it to the stainless, and bubbled the 6 smaller holes that the vacuum hose fits over, it turned out pretty nice. they end up distorting what you see when you look through them like a magnifiying glass. Gotta go eat some soup or something to get the proper sized adapter to stick on the end of the vacuum hose to do the larger holes. I'll update that when it happens.

http://img111.imagevenue.com/loc479/th_13229_DSC02602_122_479lo.JPG (http://img111.imagevenue.com/img.php?loc=loc479&image=13229_DSC02602_122_479lo.JPG)

http://img172.imagevenue.com/loc539/th_13241_DSC02603_122_539lo.JPG (http://img172.imagevenue.com/img.php?loc=loc539&image=13241_DSC02603_122_539lo.JPG)

[tybrenis]

I'm using a variable transformer to power the wire and adjust it's temperature.

[armadilloben]

Hey guys,

Thought I'd share a bit about my heat benders.

The idea is very simple. Basically, you have a nichrome wire strung horizontally. The wire is put under tension using springs to stop from sagging when it heats up. Heating the wire is as simple as applying the proper voltage across the wire.

First, you will need a length of nichrome wire and some aluminum channel. Then, you will need a spring, some scrap metal, two bolts, and some wing nuts.

The nichrome wire attaches to one end of the bolt on each side. Then, a spring is used to put the wire under tension. The process is simple - first, you tighten down the spring so it is completely compressed. Then, you attach your nichrome wire. Then, you unsrew your wing nut so the spring expands, putting tension on the wire. These pics will help:

http://www.powerpackedpc.com/images/tbcs/heat_bendert1.jpg
http://www.powerpackedpc.com/images/tbcs/heat_bendert2.jpg
http://www.powerpackedpc.com/images/tbcs/heat_bendert3.jpg

Shameless plug: I actually offer these for sale if anyone is interested, I build complete units to your specs. PM me if interested.

tybernis you win the award for strangest application of a toaster +rep lol

[tybrenis]

=D thanks mate. I am working on making a few more to sell. The offer is still up if anyone wants one, I have to fund my CNC machine, lol.

[isunktheship]

=D thanks mate. I am working on making a few more to sell. The offer is still up if anyone wants one, I have to fund my CNC machine, lol.

Haha yeah, same here... funny story, about those... I was over at my friends house, and his cousin does cnc work. I hung out with him for a while and I might be able to talk to him about getting some things cut. Really excited!!

Back to the main topic... This mod is awesome. Dell cases are pretty cool to mod, I love how the new cases open.

I'm so jealous of those of you powerful technology/tools on-hand.

Good luck with the rest, I'll stay tuned.:lick:

[|wm|]

Great job on the acrylic bubbles! Those are going to look perfect when it's all put together. Keep it up, and don't let Dell's propriortary cables and funky BIOS get you down.

[JRSCAcura]

here's a peek through the trippy bubble at the insides, for all the picture whores lol.

http://img124.imagevenue.com/loc387/th_18528_DSC02607_122_387lo.JPG (http://img124.imagevenue.com/img.php?loc=loc387&image=18528_DSC02607_122_387lo.JPG)

I whipped this up after work today to hold the fan that blows towards the PCI slots. The fan right now is mounted quite close to the front and inside a green plastic lump of crap. It's getting moved closer to the PCI slots for better cooling. I'll TIG weld it together tommorow and have it ready to mount up. It's stainless punched and flared like the window side. Should I leave the welds on it or grind them off? Also going to give it a brushed stainless finish.

http://img166.imagevenue.com/loc489/th_18534_DSC02610_122_489lo.JPG (http://img166.imagevenue.com/img.php?loc=loc489&image=18534_DSC02610_122_489lo.JPG)

http://img162.imagevenue.com/loc401/th_18540_DSC02612_122_401lo.JPG (http://img162.imagevenue.com/img.php?loc=loc401&image=18540_DSC02612_122_401lo.JPG)

[GT40_GearHead]

i would say brush it and leave the weld on, it would look great


+rep

[JRSCAcura]

I welded up the fan tunnel today and finished the outside with the weld on it. I didn't like the look of it with the weld on because I couldn't get the weld to have the same finish, it still had the rainbow colour to it because the surface undulates and I coudn't get in the dips. So I ground it off and scotch brite wheeled it.
http://img134.imagevenue.com/loc465/th_95100_DSC02615_122_465lo.JPG (http://img134.imagevenue.com/img.php?loc=loc465&image=95100_DSC02615_122_465lo.JPG)

http://img169.imagevenue.com/loc489/th_95107_DSC02616_122_489lo.JPG (http://img169.imagevenue.com/img.php?loc=loc489&image=95107_DSC02616_122_489lo.JPG)

I than drilled the mounting holes for the fan, and than drilled the fan itself and tapped it for the 1/4" 20 stainless bolts I'm using.when I take the case apart in the near future I can mount this finished piece. BTW the bolts are kind of hanging in the picture since there to long right now nd the fan is sitting off center, it will have 4 on each side of the housing to center the fan in the housing side to side and front to back.

http://img162.imagevenue.com/loc310/th_95110_DSC02617_122_310lo.JPG (http://img162.imagevenue.com/img.php?loc=loc310&image=95110_DSC02617_122_310lo.JPG)

http://img5.imagevenue.com/loc533/th_95121_DSC02618_122_533lo.JPG (http://img5.imagevenue.com/img.php?loc=loc533&image=95121_DSC02618_122_533lo.JPG)

http://img129.imagevenue.com/loc423/th_95123_DSC02619_122_423lo.JPG (http://img129.imagevenue.com/img.php?loc=loc423&image=95123_DSC02619_122_423lo.JPG)

[|wm|]

This looks great. Glad you took the weld off too. So what are those little acorn nut looking things to the left of the fan in the last photo?

[JRSCAcura]

So what are those little acorn nut looking things to the left of the fan in the last photo?

Those are stainless steel bullets left over from a project at work. I was going to use them to make a new front, with those as knobs on a fan controller. I was supossed to get a Vantec Nexus fan controller from a friend but he couldn't find it, so I ordered one instead and it came with nice aluminum knobs and buttons so I didn't need to change them. I do need to make a new face for it though out of stainless since it is just black painted steel. I may still find a use for them yet.

[JRSCAcura]

Built the second fan holder for the back of the case today that holds the two exhaust fans that blow hot air out. Finally I can get rid of the giant green peice of crap from the case.

http://img172.imagevenue.com/loc361/th_47244_DSC02620_122_361lo.JPG (http://img172.imagevenue.com/img.php?loc=loc361&image=47244_DSC02620_122_361lo.JPG)

http://img149.imagevenue.com/loc576/th_47252_DSC02622_122_576lo.JPG (http://img149.imagevenue.com/img.php?loc=loc576&image=47252_DSC02622_122_576lo.JPG)

[Zephik]

I gotta admit, that looks pretty slick. Nice work!

[Murader]

lookin Good. Did you Break your Case Cover/side or Weld? nice work Very nice. the whole bubble idea would be Sweet. +rep

[JRSCAcura]

thanks for the great feedback. Yes the side (bubbled cover has a break in it that wraps around the back, and the top and back side cover are one peice with a break as well. I did weld the corners of the breaks though to hide the rough edge, which is than sanded out to blend in. All the edges of the case panels are hemmed over onto themselves to look more substantial, and give the flat stainless some rigidity. In order to heem them over you need to relief cut the material so it doesn't fold over onto itself which leaves the corners kind of open looking after like in this pic.

where the two top front corners meet you can see the one finished corner and the one that is still open

http://img158.imagevenue.com/loc533/th_68215_DSC02554_122_533lo.JPG (http://img158.imagevenue.com/img.php?loc=loc533&image=68215_DSC02554_122_533lo.JPG)

This picture shows the hemmed over edge with the material relief cut so it doesn't overlap and the finished weld to "hide" the corner
http://img134.imagevenue.com/loc352/th_24464_DSC02623_122_352lo.JPG (http://img134.imagevenue.com/img.php?image=24464_DSC02623_122_352lo.JPG)

[ReignInPain]

Those cuts look really smooth! Very nice idea! +rep

Edit: I spy a gluegun!! My favourite weapon! :)

[Murader]

Damm i wanted to Get my Plates Hiemed But our Shop dident have the Die For it... Grrr would have been much happyer with the turn out of my Plates if we did. you can Expect a Pm from me.

[JRSCAcura]

Edit: I spy a gluegun!! My favourite weapon! :)

Thats actually not a glue gun it's my "compu TIG 3500" computer TIG welder. I'm having troubles with it though getting proper penitration. I've had to resort to using 10/32 stainless screws as a mechanical fastener for my UV lights and led bars.

http://img150.imagevenue.com/loc395/th_50950_DSC02625_122_395lo.JPG (http://img150.imagevenue.com/img.php?image=50950_DSC02625_122_395lo.JPG)

[xmastree]

Thats actually not a glue gun it's my "compu TIG 3500" computer TIG welder.
LOL!

So what's the cloudy blob of liquid on the tip? Flux? Or did you get, erm, excited when using it... :rolleyes:

[ReignInPain]

Haha! And this is my brand new CAD/CAM machine!

http://www.fyvie.net/projects/fyvienet/cutter.jpg

Fully automated, of course!

[JRSCAcura]

wicked thats the newest model too isn't it? So jealous. Hahahaa

[ReignInPain]

Not even in the shops yet my friend! ;) The firmware is full of bugs! :(

[JRSCAcura]

I had a system file extension .dll take a dump on me earlier this week so the comp is at the computer shop getting fixed, should get it back today hopefully. Windows wouldn't even start. I need to take the case apart again too make a few cuts to the case to allowt he top mount fan to fit into the case. Also need to drill and install rivnuts to secure the case onto the computer chassis. This should be a good step in a positive direction. Stay tuned for updates.

[JRSCAcura]

the nerd box has been rectified. Back to modding

[JRSCAcura]

In case some of you where wondering, no I didn't fall off the edge of the earth. Just been to busy at work and home lately. I finally did however get back to work on my comp. I've completely taken the system apart again to tweak a few details on the chassis. The big green palstic pieces are finally gone WOOT!.

I lengthened the wires from the two rear exhaust fans to run up to my fan controller and still have enough slack to open the case after.

http://img34.imagevenue.com/loc109/th_96246_DSC02642_122_109lo.JPG (http://img34.imagevenue.com/img.php?loc=loc109&image=96246_DSC02642_122_109lo.JPG)

I also cut the raised section out of the back which held the stock fans so I could mount the new fan setup.

http://img42.imagevenue.com/loc40/th_96253_DSC02644_122_40lo.JPG (http://img42.imagevenue.com/img.php?loc=loc40&image=96253_DSC02644_122_40lo.JPG)

also made a stainless back piece to clean the look of the back up a little.

http://img173.imagevenue.com/loc164/th_96266_DSC02649_122_164lo.JPG (http://img173.imagevenue.com/img.php?loc=loc164&image=96266_DSC02649_122_164lo.JPG)

http://img131.imagevenue.com/loc156/th_96259_DSC02648_122_156lo.JPG (http://img131.imagevenue.com/img.php?loc=loc156&image=96259_DSC02648_122_156lo.JPG)

the fan that cooled the card slots was ditched and the new stainless housing and 80mm fan where installed

http://img21.imagevenue.com/loc191/th_96374_DSC02652_122_191lo.JPG (http://img21.imagevenue.com/img.php?loc=loc191&image=96374_DSC02652_122_191lo.JPG)

and finally I gave up on trying to hot glue my lights in because they keep falling off after 3-4 days. Now the ends have been drilled and tapped so they mount with 6-32 stainless button head screws. nice and secure.

http://img126.imagevenue.com/loc163/th_96380_DSC02645_122_163lo.JPG (http://img126.imagevenue.com/img.php?loc=loc163&image=96380_DSC02645_122_163lo.JPG)

http://img129.imagevenue.com/loc3/th_96388_DSC02647_122_3lo.JPG (http://img129.imagevenue.com/img.php?loc=loc3&image=96388_DSC02647_122_3lo.JPG)

[JRSCAcura]

Heres the PSU exposed and you can see some of the cut wires here, I removed the wires that would have supplied power to additional HDD's I'm not going to run anything more than three so the others got nixxed.

http://img139.imagevenue.com/loc87/th_52829_DSC02653_122_87lo.JPG (http://img139.imagevenue.com/img.php?loc=loc87&image=52829_DSC02653_122_87lo.JPG)

heres the bottom of the circuit board which I un-soldered the unused wires from, and later soldered in a 10" Super Street UV light (forgot to take pics of it) The CCL you see in the picture had extended wiring and because of the lose of voltage from the extra length didn't light up worth a sh*t so I hard wired the other one in I had.

http://img169.imagevenue.com/loc238/th_53379_DSC02660_122_238lo.JPG (http://img169.imagevenue.com/img.php?loc=loc238&image=53379_DSC02660_122_238lo.JPG)

http://img18.imagevenue.com/loc226/th_52836_DSC02654_122_226lo.JPG (http://img18.imagevenue.com/img.php?loc=loc226&image=52836_DSC02654_122_226lo.JPG)

heres some of the left over wires

http://img21.imagevenue.com/loc135/th_52814_DSC02658_122_135lo.JPG (http://img21.imagevenue.com/img.php?loc=loc135&image=52814_DSC02658_122_135lo.JPG)

I clamped my acrylic to the edge of a table with a peice of angle iron and heated the area across where I wanted to bend it and than bent it 90 degrees. I drilled and tapped 2 6-32 holes for the acrylic to be attached to the case so it doesn't move, it's held with 6-32 stainless button head screws.

http://img174.imagevenue.com/loc260/th_52803_DSC02656_122_260lo.JPG (http://img174.imagevenue.com/img.php?loc=loc260&image=52803_DSC02656_122_260lo.JPG)

http://img11.imagevenue.com/loc36/th_52822_DSC02659_122_36lo.JPG (http://img11.imagevenue.com/img.php?loc=loc36&image=52822_DSC02659_122_36lo.JPG)

and one final pic for the update is my stainless fan controller front to go with the theme. Looks better than original painted one I think, still need to mount the brackets on it to hold the controller also modding it a bit so I can hide an lot of wiring and clean up the looks of the inside.

http://img172.imagevenue.com/loc251/th_52806_DSC02657_122_251lo.JPG (http://img172.imagevenue.com/img.php?loc=loc251&image=52806_DSC02657_122_251lo.JPG)

[JRSCAcura]

I made brackets to hold the top of the case and the side panel together, as well I sleeved the top fan cable while it was apart.

http://img126.imagevenue.com/loc192/th_94552_DSC02661_122_192lo.JPG (http://img126.imagevenue.com/img.php?loc=loc192&image=94552_DSC02661_122_192lo.JPG)

The screws that hold the case together are 1/4-20 stainless button head screws, I used rivnuts for the screws to attach to so there is no need to try and put on or remove a loose nut since you couldn't get to them once everything is tight.

http://img111.imagevenue.com/loc67/th_94558_DSC02662_122_67lo.JPG (http://img111.imagevenue.com/img.php?loc=loc67&image=94558_DSC02662_122_67lo.JPG)

My second LED light bar has been installed in the top rear section of the case.

http://img9.imagevenue.com/loc145/th_94564_DSC02663_122_145lo.JPG (http://img9.imagevenue.com/img.php?loc=loc145&image=94564_DSC02663_122_145lo.JPG)

the case partially done now

http://img37.imagevenue.com/loc205/th_94571_DSC02664_122_205lo.JPG (http://img37.imagevenue.com/img.php?loc=loc205&image=94571_DSC02664_122_205lo.JPG)

http://img44.imagevenue.com/loc146/th_94578_DSC02666_122_146lo.JPG (http://img44.imagevenue.com/img.php?loc=loc146&image=94578_DSC02666_122_146lo.JPG)

can't forget the obligitory night shot
http://img7.imagevenue.com/loc99/th_94969_DSC02669_122_99lo.JPG (http://img7.imagevenue.com/img.php?image=94969_DSC02669_122_99lo.JPG)

[JRSCAcura]

3 updates and not a single comment? :?

[Indybird]

Very cool mod so far, cant wait to see it done.

By the way is that a Dell XPS?

[GT40_GearHead]

nah don't wary man, you are doing a great job !

+rep

[jdbnsn]

3 updates and not a single comment?

Funny you should mention it, I left you a comment today...

click me...http://www.thebestcasescenario.com

[SgtM]

Congrats on making the front page man! This mod looks killer! +rep

[Omega]

The mod looks great, man. +rep

[moon111]

Great looking work on the case. Although I really liked the gas filler door on the truck, that was nicely done.

[JRSCAcura]

awesome thanks for the comments everyone, and making the front page WOOT! Can't believe it. More to come.

[Acey]

Love the colours.. looks like some Las Vegas / 1960s / red light district's lighting effect... *thumbs*