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Project Arclight

- - - - - Actylic Servos Azza Ratx Dual loop fully enclosed

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#1
tobyak

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Behold my latest creation to be

Project Arclight will be a huge case built on an Enermax Fulmo GT chassis with some serious power behind it also provided by Enermax in the shape of the mighty Platimax 1200watt psu

Te Arclight will be an all acrylic outer shell with a double action doors and servo actuated fan intakes that will open and close based on fan speeds, the shell will have a double tone look with layered panels of black and flourescent blue to accent every edge even the 100s of vent parts will have glowing edges, the interior will be a partitioned system very much like the custom partition for my other project "Sulaco" but with far more refinement

Much of the details i would like to keep slightly underwraps untill I post them for that extra mystery, heres a little peek at the exterior

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several sponsors are already assisting me on this build and there help is as ever massively appreciated i simply would not be able to do this without them

Acrylic and solvent supplied by Hindleys. These guys are amazing, catering for 100s of different types of materials from plastic to metal and everything in between. And allays happy to answer even the craziest of questions a modder like me can ask

Massive thanks to Enermax for supplying a Fulmo GT, Platimax 1200wall and a vast array of case fans from there amazing Vegas range

Thanks also go to Bitfenix for givign me so much on my last project that i have enough spare to add to Arclight


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Stay tuned for a lot more to come........

#2
tobyak

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Arclight was origionialy designed for the Enermax fulmo GT a huge and brillicnt case, but time has marched on and Azza have offered me the chance to use there superb Genesis 9000, so a little redesigning was called for,

Concepts for the intakes have been redesigned to better fit the new chassis and all the electronics have been brouht in and in some cases teaching myself arduino voodoo

Heres the first batch of parts going in to the chassis

the origional blade design and array have changed slightly from this
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to this
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The array control mechanism of a pull rod attached to a servo will remain much thesame as the origional

Some parts will need to be scrapped or completely changed to fit the new body shell such as the origional concept for the sides Posted Image


the new version will be a wait and see but they look great in the planning


Well this project will need a huge number of mechanical and electronic parts in top of your typical PC set up


This arduiuno kit courtesy of Phenoptix is a great start to the project and will be controlling several of my lighting systems including a rather clever hack of a LOL shield
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LOL shields and old school bar graphs will be making quite an appearance as accenting lights, and yes there will be larson scanners
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Servos and actuators will be making a big appearance including several mechanized fan intakes and a large front panel "shield"
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And to wrap up this update and REBOOT, Kingston have graciously given there support and provided some of there swesome products

the amazing HyperX 120gig SSD
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and a quad kit of DDR3 2400MHZ RAM
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Stay tuned

#3
tobyak

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Just a little update today

An absolute ton of cutting and sanding today


Well i dont have access to a lazer and i need a lot or duplicate pieces to were rocking it old school with a stencil
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And what better to cut out my many many parts than a home made table saw, complete with mitre fence
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Problem.... no sharpie..... solution... stick paper to plactic cover on acrylic and use engineering pencil... copy template.... move.... repeat.... over, and over
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and now its on to cutting

first up divide the sheet up in to manageable blocks
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then drill holes for turning the cutting blade in
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some more cutting to further separate each component
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first half done, all rough cut
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bit of refining the shapes to reduce sending
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sanding time...... 1 of 24
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and yes that is a dyson taped to the extraction port

all done for the day, 24 pieces of the main intake array rough cut and rough sanded
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i may never want to see acrylic AGAIN after this build....

#4
tobyak

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Although ive had a long break from posting my work has continued, i finally have time to sit and type

So i shall pick up where i left off

The rough cuts were plastic welded in to pairs of one blue one black each with liquid dichloromethana injected in to edges to form 12 completed pairs

After coming off the sander for the first time the edges are still as rough as a badgers behind but the biggest thing to address is the notch in the top that neither the belt or disc sander can get in to

So out come the hand files
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4 hours later and the stack is complete
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The edges still needed quite a lot of refining so on to the hand sander

.... I broke my sender.... just imagine a lot of swearing and a run to the shop....

After sanding...
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A little test fit and tease before polishing the edges of each intake
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Three hours of polishing with a drill press slightly modified to server as a bench grinder/buffer and we have....
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another 2 hours and we have a result
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A long time to finish from rough cut to finished intakes but they do look damn good if i do say so my self

Next up, modding the roof and base plastics

#5
tobyak

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Time for the update that has been a long time coming

As most of you know the case changed from from an Enermax Fulmo GT to an Azza Genesis 9000 as the Genesis offered a stronger frame and more internal space to work with.... before work started it looked like this...

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and the chassis itsself looked like this..

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IIt is a brilliant reverse ATX chassis, very well made and strong enough for an 16Stone man to stand on, BUT as is the case with mods some structure needed to be removed so after an hour with a drill we have

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Frame all ready to measure up the floor panels and internal enclosures


As this case is somewhat modular in terms of its plastics i was freed up to mod sections in waves rather then all at once

starting with the floor plate, this would also serve as a test run for the metals replacing all the red inserts in the bezels

The base plastics are very heavy built and massive

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But the vents need to go to make way for metal inserts

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Perforated plate form ebay makes freat replacement vent intakes for the floor

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Ahh hot glue what would i do without you....

#6
tobyak

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All good mods start with a plan.... well thats me out of the window

But at least i got some penile work done measuring up the plastics for the enclosures


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Overkill 120 grills make handy stencils of.. erm... overkill 120mm grills

Acrylics cut to size and welded with Hindleys Dichloromethane

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Ahhhh all snug fitting

The psu, most of the tubing and a very thick 60x240mm rad will be housed under this.

This 60x240mm rad to be exact, with a pair of Enermax TB silence 120mm fans on pull configuration

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Sharing the floor will be an Enermax Maxrevo 1200Watt fully modular PSU... it is MASSIVE

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I may have to many spare cables

To kill some time waiting for some parts i partook in another of my favourite basstimes... no prizes for guessing what these 2 SciFi icons are

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Plastrics cut and marked up for the optical bay covers, the optical and hdd bay area will house both pumps as well as most of the tubing of the twin loops and access hatched have been cut in to the floor compartment to get to rad fittings and install cables and tubes

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#7
tobyak

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First test fit of all the enclosures plus checking that weight of the res holders will not warp the top of the enclosure

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Pass through holes cut for Tubing to and from the twin res, due to access the PSU, bottom Rad and main PSU looms are already installed in the lower enclosure

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Well that's enough of the enclosures for now on to the roof again

After installing the rails and letting the welds cure in go the 12 vent components in to there sockets, until the retention arm goes in they can move through 140deg

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I suspect that Dust is going to be an issue... just a hunch

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but DAYUM they look good lit

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I made a small plate to hold the servo, amazingly a tiny 9g servo can pull the vents, the full array weight close to 3lb

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Yes i know the metal wire is a little ghetto but im waiting on an RC pull arm

#8
tobyak

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Some of you will know me as the designer of project Sulaco, Sulaco was started at the very start of my modding escapades and much has changed, Sulaco has not been scrapped much of its concept and ideas are in Arclight, an updated build to reflect my more developed skills

#9
tobyak

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With most of the structure and covers complete i can start the loops, that was a tad more involved than i expected, clearance between the top of the PSU and the Top of the floor enclosure is just big enough to get a 1/2 OD tube through... and i need to get 6 through it

Starting off... install res and attach to mounting blocks on the floor, plus attaching the main tubes from the CPU and MB waterblocks and taking then to the bulkhead

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Next up install pumps and run feed tubes through the floor plate to the lower rad and run the outputs to the waterblocks, as i side thought i added a fill port and hooked up the top 360 radiator to complete both loops

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Well at this stage i was going to fill my loops but my daughter has other ideas

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After a short fight that i eventually won with a stunning pile driver i finally filled the loops

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yay its leak free.... well it is now, it kind of wasn't but lets not talk about that.... nothing to see here... move along

#10
tobyak

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Construction is 90% complete and its already in service as my main game machine, side door needs a window and massive changes are going to be made to the front of the case

So im going to show off some of the key features so far

modified intakes and bottom deck enclosure

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Access ports

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Concealed tubing

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Tidy tubing with bulkheads

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Back plate mounted SSD and HDD

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Damn good lookin if i do say so myself

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MUCH MORE TO COME

#11
andybones12

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Bleeding hell that is an awesome build [-(
Took me ages to red through it all.
Some very artistic designs with the reservoirs.Nice sketches at the start.
Love the blue coolant and the air fins in the roof.
Must be an entry in a competition ;)

Andy

#12
tobyak

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Thanks Andy

Still a little to do, thinking how i can mod the door, it hast to have a window of som kind, and the front is getting another motorized gadget of som kind, maybe a drop down CM2 style plate with vertical fan control behind

#13
vitesse

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Nice work :)

Had to google the LOL shield, its an LED matrix right?

Presumably using the Arduino you'll be controlling via usb? I did a similar thing for lighting control on my last build and used one of these:http://www.pc-control.co.uk/minibee_info.htm I found it was a little more robust than using a PIC/Arduino as it already incorporated a driver IC on a small footprint otherwise I'd have been having to add transistors although that wouldnt probably work with the matrix.

Looking forward to seeing this coming along :)

#14
tobyak

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It is finally time for an update
 
As most of you know by now a short while ago i acquired a small CnC mill with which to being my twisted imaginings to reality.
here is how it went
 
 
As i completely forgot where i left my shots of my mill here is a stock shot of the exact same model, I was rather dubious of the quality of the machine as it is a cheap ebay Chinese machine but after ironing out a few bugs i do haft to say this is a great machine.... i had to mod it of course
 
i had heard that as the boards in the control boxes were generic i should find additional headers for a probe and limit (home) switches
 
just what i wanted to find, headers for limit and probes, idon'tcurrently have a need for a probe but a limit (home) switch is a must have
 
finding areas to mount the switches was a little tricky given the spaces i had to work in. i wont bore you with the details/
 
 
starting simple learning my way around the machine and everything went well..... if you forget the time i put an engraving bit part way through my T slot bed. the end result for a simple quick run was rather impressive although settings still needed some refining/
 
the first proper case parts to roll off are roof intake vents, the original vents took months to make by hand but with a cnc i can improve on them and get perfect results in just a few hours to cut all 30 of the new intakes (more about those in a later update)


#15
tobyak

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once my confidence with the machine grew i finally ventured in to alu milling.... with TERRIBLE results, screaming mill and terrible tooling marks. after 3 weeks i finally worked out what was wrong, no coolant/lubrication, so out came the WD40 and away we went

 

the arclight main bezel for the front of the roof if a plane sheet of 1.3mm alu shaped and contoured to fit in to a recess in the existing factory plastics

 

to say that the milling went very well would be an understatement, the results are fantastic, i will be doing way more alu work in the future including my own custom grills for sale

 

the lesson here...... WD40 is your friend

 

 

on to the REAL work

 

some time ago i designed this bezel for the arclight based on the mk7 ironman cheat arc, at the time i did not have the ability to bring it to life..... now i do

 

and so the madness begins

 

starting with a massive block of plexi (300x200x20mm) and a psychotic grin, the mill went in to action, to keep a fairly good finish and prevent melting of the pexi, i invested in some coolant (you will spot the chips chance colour a few times depending on the coolant i am testing in each phase)

 

 

the endmills i am using are designed to go no deeper then 12mm and i am going down to 20mm so lots of coolant is being used to try to push the working limits, and thankfully it worked far better then expected

 

the above shots represent 3 hours of mill time, going super slow to avoid trouble



#16
vitesse

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Now thats what I need :D

 

Never got on with CNCs, tried programming a lathe once and all was going well till it started attacking the chuck jaws with the parting blade. Envious of you there mate :)

 

Still intrigued to know, how are things going with the arduino? Currently working on my own PIC USB interface and its a struggle



#17
tobyak

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arduino is going great, im the middle of programming it to run a LOL shield as a massive larson scanner with all of the leds on breakout wireing.... i may never want to look at solderwire ever again



#18
vitesse

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Never really thought of using breakout wiring long-term, thats food for thought :)

typically ive got the odd pot, lcd etc soldered up to breakouts with pin ends just for breadboarding stuff.

 

The CNC work looks sweet mate, I take it the microswitches you added were for referencing the axis? Kind of annoying that the manufacturer doesnt fit them to start with for the sake of a couple of £ and a bit of wire.



#19
tobyak

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continued......
 
after getting the centre to full depth the tricky work can begin, the endmills i use have a flute that is 12mm long, this limits me to 12mm depth or i will not get any kinf of chip evac when cutting......... but i ignored that and took them 20mm deep
 
mach3 with custom skin displaying tool paths and the current positions of the axis, just about to start fork on the epics above
 
i am skipping sections of programs or making ones that leave out large areas of the design specificaly to allow me more sway room as i get closer to completion
 
first roughing (horizontal roughing) for one of the arms, using vegitable oil (liberated from my chip pan) as an ad hoc lube, as this is cast plexi it melts if you even breath on it. the tooling looks a bit rough as ive not cleaned up all the debris in the shot... the results even at extream depth were very pleasing, although oil as lube does make the chips look horrible and a nightmare to clean up
 
 
the eagle eyes may notice the slight lip on the bottot of the right arm, after finishing the left i decided to change max depth to 19.5mm to give me a ,5mm tab to help keep the part stable later and to stop the coolant from destroying my baseboard


#20
tobyak

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continued.... erm.... some more
 
back to milling the center this time leaving zero stock, this was make or break, if i had planned anything wrong the whole piece would be ruined, but it seemed that lick was on my side
 
full cleanup can wait until all the cutting is complete
 
for some scale
 
many many hours later we have this, i quite like the liered effect of the roughing but this is destined to have a smooth finish
 
finishing took less than an hour, meer seconds compared to the time the entire roughing took
 
and this is what we and up with
 
 
well thats me up to date, more updates in a week





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