Cygnar Storm Strider Casemod

[msmrx57]

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

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

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

[monkeyfun]

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

You can do that? Hmmm...

[msmrx57]

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

[monkeyfun]

Update #19: Main Enclosure
Count Down: Only 18 more days until PAX 2011.

TICK TOCK TICK TOCK TICK TOCK

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

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

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

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


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

I finally got all of the enclosure posts completed.

Then I began attaching the walls.

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

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

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

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

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

I finally attached the back plate to the posts.

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

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

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

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

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

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

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

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

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

[monkeyfun]

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

I have good news and bad news.

[monkeyfun]

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

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

[SXRguyinMA]

[monkeyfun]

Update #20: More Casting! Good news and bad news.
Count Down: Only 15 more days until PAX 2011.

HazardFactory’s

First off, I’d like to thank Rusty @ HazardFactory for all of the help and the use of his shop. Without his help, this project simply would not be. Rusty:

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

The furnace had to be heated up and aluminum melted.

The Furnace

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

Melting Video

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

Then of course, we poured the aluminum:

Pouring part 1:

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

Pouring part 2:

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

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

Reveal part 1:

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

Reveal part 2:

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

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

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

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


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


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

Still not losing momentum! Mod on my friends!

[billygoat333]

That is awesome! love the use of casting!

[mDust]

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