Project 2en 05/02/07

[yakyb]

Welcome To Project 2en

The idea behind this MOD is to produce something that will give an excelent cooling solution
whilst running near Silently

The Name 2en refers to it using two http://i102.photobucket.com/albums/m92/YAKYB/AKASA.jpg Zen cases to create a cube Mod


This Mod has been inspired by
the excellent Koradhil's Gemini Mod http://www.korazu.com/page.php?al=gemini using the Yeong Yang Server Cube
And by the legendary Defyant's HP Res 3 Mega http://www.thebestcasescenario.com/forum/showthread.php?t=550&page=8
there ae a few others and i will update the Log as i Find them.


AnyWay on with the Worklog

The Case as Mentioned Earlier is the Akasa Zen. I chose this case as it was extremely cheap and Very Well Made. I would have used a couple of old dells or compaqs but i needed to use to cases of exactly the same size. Previous experience with AKASA has been Excellent with the Eclipse 62 used on my First Scratch Build So i decided to continue using them.
http://i102.photobucket.com/albums/m92/YAKYB/SSL11109.jpg

Firstly i needed the cases to be stripped

http://i102.photobucket.com/albums/m92/YAKYB/SSL111112.jpg http://i102.photobucket.com/albums/m92/YAKYB/SSL111132.jpg

Then unlike the Gemini i wanted my Window on the Right hand side (My computer always sits on my Left) so that i can see inside at all times so i had to invert one of the cases (often confused with BTX)
http://i102.photobucket.com/albums/m92/YAKYB/SSL111162.jpg http://i102.photobucket.com/albums/m92/YAKYB/SSL111242.jpg

PS I now Hate Riveting

[yakyb]

Part 2
You are Not a true Modder until you cut your first Window (thats how i feel anyway), Installing LED Fans and CCFLs is all well and good (but dont get me wrong is a fantastic way to start) but doesnt really require any skill - not that i have much

Cutting my First Window Did feel like a rite of passage

The Case Will almost never Move (except when i hope to Move house later this year!! :-) ) therefore the Weight of the Case is not an issue in fact i would prefer that the case was heavy and therefore dampen any vibrations caused by the fans that will be installed so i have decided to Bondo the entire Outside of the case

whilst this appears very messy at first (and is a PITA to sand i can tell you that it looks a lot better in Person)

these 2 photos show a comparison between the surfaces after about the third coat of bondo. I used the method of as many small layers as possible in an attempt to creat the smoothest surface i did about 5 layers total each with a good sanding in between.
http://i102.photobucket.com/albums/m92/YAKYB/SSL11130.jpg http://i102.photobucket.com/albums/m92/YAKYB/SSL11131.jpg

once the side panel and the two tops where done i gave them a quick coat of grey primer in order to check for any last bumps and to even the colour accross it
http://i102.photobucket.com/albums/m92/YAKYB/ssl11179-250.jpg

[yakyb]

PART 3

Woohoo some more electronics stuff arrived today
http://i102.photobucket.com/albums/m92/YAKYB/ssl11193-250.jpg
http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11258.jpghttp://i102.photobucket.com/albums/m92/YAKYB/400300SSL11260.jpg

anyway onto the Window..

a few cuts into the acrylic

http://i102.photobucket.com/albums/m92/YAKYB/ssl11181-250.jpg http://i102.photobucket.com/albums/m92/YAKYB/ssl11185-250.jpg

http://i102.photobucket.com/albums/m92/YAKYB/ssl11216-250.jpg

i then ordered some of this Foam stuff on Ebay

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ih=016&sspagename=STRK%3AMEWN%3AIT&viewitem=&item=260077155447&rd=1&rd=1

Thanks Flissy

I intended to use this as vibration absorbtion for fans etc but when i got it home i decided to give it a heat test from my heat gun and it is very resistant to heat so whilst im not going to do anything really daft with it i shall use a lot more than i first intended.

[yakyb]

PART 4
Okay been working on some electronics as i mentioned earlier i want something that will run Quiet and also give excellent performance (read Overclock very well)
so i have been working on a project box to convert it into a control panel for my computer. not only will it contain the switches and Junctions for all Leds it will also act as a fan controller to switch between 12V 7V and 5V supply for the fans, it will also house the Power and reset switches that will allow a bypass of the front power switch which will be electronically locked

here are a few circuit diagrams that will be included within the case

Led Wiring
http://i102.photobucket.com/albums/m92/YAKYB/LEDSimple2.jpg

Fan Control
http://i102.photobucket.com/albums/m92/YAKYB/FanConfig.jpg

Ibought a Project Box from Maplin in order to house the controls for a array of switches that will select the Control Voltages for the fans as shown in th above diagram
I Made this design (using Paint LOL!) in order to map out the placements for the terminals and switches
http://i102.photobucket.com/albums/m92/YAKYB/untitled.jpg

http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11233.jpg

here are a few snapshots of the finished product

http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11248.jpg http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11256.jpg

http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11242.jpg

Oh and for those of you who like problems check this out my soldering iron got a bit to close to my z680's
http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11238.jpg

[yakyb]

Part 6

Onto the Water Cooling System This will be my first attempt at Water cooling but i have done Quite a bt of research. what struck me about WC is the price of the rads.

i picked up this one for £7.50 on Ebay (Motocross Intercooler)
http://i102.photobucket.com/albums/m92/YAKYB/SSL11139.jpg

and this one for £6.00

http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11234.jpg http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11236.jpg
http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11237.jpg

as you can see however i need to get the fittings to fit i had planned to use to solder but it didnt want to stick to either to the rad or the fitting. Any ideas guys?

[Intrance]

Part 6

as you can see however i need to get the fittings to fit i had planned to use to solder but it didnt want to stick to either to the rad or the fitting. Any ideas guys?

From: Clicky (http://www.epemag.wimborne.co.uk/solderfaq.htm#clean)

"Firstly, and without exception, all parts - including the iron tip itself - must be clean and free from contamination. Solder just will not "take" to dirty parts! Old components or copper board can be notoriously difficult to solder, because of the layer of oxidation which builds up on the surface of the leads. This repels the molten solder and this will soon be evident because the solder will "bead" into globules, going everywhere except where you need it. Dirt is the enemy of a good quality soldered joint!"

Once you have cleaned it up try and put some flux onto the rad and connectors that may help? Hope so.

Also consider the size of the rad as it will wick away the heat very quickly (well, this is what it was deisgned to do!!) so you may need to get alittle more heat into it.

Hoep this helps?

[yakyb]

yeah i think that is the problem i have been informed of it on another forum thanks intrance:up:

[tybrenis]

Your best bet is to sand down the joint to be soldered, apply some flux, and use a torch and some thicker gauge of solder to get it soldered pretty easily.

[Drew]

Just a couple of things.....

Moto-X rads? That NEVER ought to overheat! Fair play, you dont mess about...

Bondo (filler here) over the whole thing? wont it be brittle?

Not criticizing, looks like a cool mod!

[xmastree]

Led Wiring
http://i102.photobucket.com/albums/m92/YAKYB/LEDSimple2.jpg

Noooooo... don't put them in parallel like that.

http://i50.photobucket.com/albums/f341/chrispollard/LEDs.png

Like that instead

[Foxtrot9000]

you could always use silicone to hold thos things in the rad =) that stuff is awesome, i worked under a plumber for half a year and we use silicone for everything. in alot of cases it will be the only thing holding a basin to the underside of a counter. just my .02

[edit] actually i thought about it for a min and i dont think i would use silicone as the sole thing holding it in. but it would def make a good extra just in case, if you know what i mean. and its cheap

[yakyb]

Noooooo... don't put them in parallel like that.

http://i50.photobucket.com/albums/f341/chrispollard/LEDs.png

Like that instead

i see what your saying allows for failing accross a smaller range of LEDS i.e should one fail you would only lose 2 others as opposed to 8 ill proably take you up on that advice cheers


also this thing is in no way brittle whatsoever its absolutly solid however i am a little wary about drilling a blow hole in the top but that could be repaired very easily

[xmastree]

i see what your saying allows for failing accross a smaller range of LEDS i.e should one fail you would only lose 2 others as opposed to 8 ill proably take you up on that advice cheersIt's not about failing, it's about tolerances. LEDs drop a certain voltage, and if one with an abnormally high voltage is directly in parallel with a low one, the lower one will take much more current.
The way I showed ensures they all take the same current.
And with LEDs, it's the current which is important.

[yakyb]

Part 6

right been a little while since my last update i have been experimenting with a couple of things. However firstly ill show you one of the successes in order to best Route theairflow accross the motherboard i wanted to remove the corners of the case so that the air is directed best.
i thought the best method of doing this would be to bend a sheet of acrylic.i bought a draper heatgun from tooled-up.com and on the lowest heat setting slowly warmed up the acrylic by moving the heat gun side to side until it bent under its own weight. The peice shown below is actually a clear peice however using a tutorial i will link to later (when i find it again) i cleaned the acrylic with some white spirit then sanded the underside with 400 600and 800 grit sandpaper cleaned up again using white spirit before applying 5 thin coats of paint to create the effect you see below.

http://i102.photobucket.com/albums/m92/YAKYB/DSC00032.jpg http://i102.photobucket.com/albums/m92/YAKYB/DSC00033.jpg
http://i102.photobucket.com/albums/m92/YAKYB/DSC00034.jpg

As you can see this will have the added effect of housing my pump (MCP655) and will also route the wires from my PSU which will be housed on the other side of the case.
Note also the foam used in the top left picture ill get a shot with a test mobo in at some point so you can see it in full effect but i quite like it any opinions?

Next up is my Bondo area thought i would show you a pic considering i have done so much on this case

http://i102.photobucket.com/albums/m92/YAKYB/DSC00057.jpg http://i102.photobucket.com/albums/m92/YAKYB/DSC00056.jpg

this is the left hand side of the case (that which will hide the Psu and Radiators
following this tutorial
http://www.mnpctech.com/120mm_FanDuct_Computer_Mod1.html
i intend to make a side intake on this side that will draw extra cool air into case to be drawn out the rear

here are a few snapshots of the WIP
http://i102.photobucket.com/albums/m92/YAKYB/DSC00042.jpg http://i102.photobucket.com/albums/m92/YAKYB/DSC00043.jpg
http://i102.photobucket.com/albums/m92/YAKYB/DSC00044.jpg http://i102.photobucket.com/albums/m92/YAKYB/DSC00045.jpg

I have done a fair bit more modding but i will show you when the time is right.

[yakyb]

Part 7

Things have really moved on since part 6 (I can now see the end in sight)
ok couple of non mo related photos first.

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00062.jpg http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00014.jpg

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00030.jpg

everyone has a modding Buddy This Little girl is mine (well actually my sisters). Kissy the cat. secondly dont you just love SupCom, its a shame my processor craps out after about 200 or so units so im going to have to wait for 2en to be finished before i can really play it (godammit)
finally as you my have noticed i am modding out of my room and this is its current state. my Gf has been very patient with it but i think i may have to spend a while tiding up at some point,

Right then on with the Modding
Buitl up my XSPC rad with dual Fans and whilst i know that i should have a shroud in place its not really an option as space (even tho im using two cases) is at a premium.

i plugged the two fans into my Fan controller and it works silently at 12v let alone 5v so very happy with this part.


http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00032.jpg http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00031.jpg

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00040.jpg http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00035.jpg

I Left you in Part 5 with this Photo
http://i102.photobucket.com/albums/m92/YAKYB/400300SSL11236.jpg

turns out that the Rad is Aluminium and therefore can not be soldered. this left me with only one option. resin and glass fibre.

this is my first time ever working with this stuff so excuse the mess. when i use this stuff in the future i will definately set out molds for this stuff to avoid the run off that occured here, however the thing is more than firm and has since been coated with black tape so im very happy.


http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00044.jpg http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00046.jpg

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00049.jpg http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00051.jpg

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00052.jpg

note the run off. i would have been happier had this not occured but you live you learn.

next onto the mounting im going to need two holes in the roof of the case so

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00055.jpg http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00058.jpg

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00056.jpg

and heres the mounting

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00063.jpg http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00060.jpg

http://i102.photobucket.com/albums/m92/YAKYB/part7/DSC00059.jpg

im obviously going to replace the tape at some point this week just trying to think of the best method.

Anyway untill part 8 All the best and Keep modding :-)

[yakyb]

Part 8
Right dont you just love easter 4 days off work is fantastic. spent friday saturday sunday with my GF as she has been on holiday all week. that left monday to get some modding done.
since Part 7 i bought some Black MAtt Paint to paint the Grey of the case. and i really like the difference its made after only 3 thin coats (Black is very Forgiving!!!)

what i needed to do today was create a mount for the second Radiator.
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00095.jpg
If you Look Carefully you can see the clear Acrylic Mounts that were bent using a Heatgun. the screwed into the roof of the case and like wise to the mounting brackets on the XSPC Radiator.
Now Whilst this is technically capable of Holding the Rad up on its own i didn't want to have to trust on it (esspecially when at full weight)

so i measured up and cut a long strip of acrylic.(excuse the 1970's glasses they are very freaking old)
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00079.jpg

and for size comparison against the case
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00075.jpg

what i intended to do was to create a bridge that would go over the intended slot for the PSU and provide a Lower support for the Rad.
so i whipped out my heatgun again. and started some more bending.
here it is in Position
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00088.jpg
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00089.jpg

I then Performed the Same Procedure as i did in Part 6 in creating the Pump Shroud, by sanding the underside of the bridge then using a enamel black spray paint on the sanded side, to create a shiny Black surface. it really is very shiny just needs a little clean for final instalation.
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00103.jpg
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00099.jpg
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00091.jpg
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00092.jpg
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00102.jpg

as you can see in the Photos there are also some bent acrylic Brackets attached to the Bridge which will go over in the next update as they still need tidying up a little
oh and for those of you who are interested the fans are set to pull from the front of the case Through the XSPC Rad then out the back throught the range rover rad.

and finally a couple of last pics with the side mounted on. which incidently is the same side i showed being bondo'd in Part 6.
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00098.jpg
http://i102.photobucket.com/albums/m92/YAKYB/Part%208/DSC00096.jpg

I would be very grateful for your comments on my progress so far as i can really see the end in sight now.
I just have some

Tube routing,
LED wiring and Mounting,
REservoir mounting,
Front design
Oh and im Probably going to redo the electronics Part as i dont have a clue where its all going to fit lol two cases and not enough room.

anyway as i said comments would be appreciated

Mod On!!