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Thread: Building a case from scratch?

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    Senior Member Pob255's Avatar
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    Building a case from scratch?

    I'm considering build a whole new case from scratch (would be a month or two before I start minimum)
    Just wondering if any one has tried this? any links to good examples?
    One reason is that I'm currently considering a whole new lay out for air flow, I'm planning on sticking with air cooling not moveing to water cooling.
    Standard case airflow layout is front to back, psu above motherboard.

    I'm currently considering bottom to top. mounting 3x or 4x 120mm or 140mm fans in the top, psu below motherboard, minimal front/back/side air vents and a massive filter covered hole in the bottom.
    The rough idea is all the air will get sucked up from below and blown out of the top.

    Any sudgestions on materials? (fairly low cost) I'm pritty sure I can borrow the tech workshop at the school I work at, so I should be able to get access to some decent tools/machinery and hopefully basic materials cheap (nuts, bolts, sheet metal, etc)
    I'm pritty sure I can get a motherboard tray out of an old cheiftec case from work, it's a p2 350mhz so is schudaled for the pc graveyard and I'm sure I can divert the the motherboard tray on route

    I was thinking of useing slotted angles (not sure exactly whiat this stuff is called) to make a frame and bolting pannels onto it (going to have a bit of a heavy industry look to it)
    This sort of stuff


    I'm going to do a load of plotting and planning before I start this one.

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    Senior Member Hicks12's Avatar
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    Re: Building a case from scratch?

    i was thinking of building my own too. If i find a decent guide etc ill post it here.

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    Re: Building a case from scratch?

    AS well as the motherboard mountings if you were going to use any pci cards then I suspect that you would need to make sure that the pci card holes and screw-hole mounting bit came with it, as that could be a problem to line up.
    For just seeing if it'll work before you make a nice one it may just be easier to get an old case [or dirt cheap one] that is too big, [EATX?] and then play about with mounting stuff in different places in there.

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    Re: Building a case from scratch?

    I've dopne that once before it's my current case
    http://forums.hexus.net/chassis-syst...e-project.html
    Took an old server case and conveted it to ATX, all that was required was drilling new holes for the motherboard standoffs, the tricky and annoying part was the differnce in rear IO shield size.
    But that doesn't matter as I'm looking at useing a motherboard tray, it basically the same as the one used in the old Li Lan cases, like this

    Execpt the old cheiftec one at work doesn't have a fan.

    When you think about it the rest of a pc case is just a metal frame with pannels hung off it. I could salvage drive bays out of an old case if needed.

    My main current questions are what materials to use? something that is relatively easy to work with and construct without that great a skill range.
    I don't have any experince with welding, I should be able to access work benches, vices, standing drills, machine saws and even a lathe. I was thinking if that perforated angle stuff as it should be more than stronge enough and I can bolt it together.
    Last edited by Pob255; 14-04-2008 at 01:09 AM.

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    Re: Building a case from scratch?

    I remember thinking of doing this a couple of years ago. I went to Project Logs and had a look at what other people were doing. Quite a few people are building cases from scratch. I was particularly impressed by the Japanese inspired case made from wood (called Sangaku IIRC).

    There was a material made from aluminium square tubes, with plastic connectors (corners and T-pieces) that looks very easy to build a case from and attach panels to. For the life of me, I can't remember the name of it I'm afraid. I think it may have been used to make aquariums originally, but really can;t be sure.

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    Re: Building a case from scratch?

    Thanks, nice site, some intresting built from scratch cases there. and very professional looking resaults.

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    Re: Building a case from scratch?

    Well after lloking through some of that, there are some spectacular build there.
    now I don't really know where to go with this : keep it a simple box with my idea for up/down only air flow or while keeping to the same basic air flow principle but do something non square and more intresting looking.

    I've been have a play with sketchup to see I sort out some rough ideas . . . and getting very cross with it.
    It's taken me nearly 3 hours to knock up a rough template for my ultima90, given a couple of weeks I'm sure I'll get used to the interface.
    However I'll probably just fire up 3ds max as I know my way around that blindfold

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    Re: Building a case from scratch?

    Before I forget I got permission to divert the entire pc whole from it's way to the scrapheat
    So I got my none too good camera and took some pics

    One achent CheifTec case


    round the back, you can see the rear of the motherboard tray here


    Open her up, you can see the tray reaches almost to the front of the case, plenty big

    I'm going to keep all the old bits (once I've dusted them) for use as a test setup
    P2 350mhz, 20gb HD (seagate I think), 16mb S3 agp card, 10mbit netcard, cdrom, floppy, souind card (soundblaster I think) 250w PSU and AOpen motherboard. Don't know about the memory.
    The Case measures, 480mm high(not includeing feet), 420mm long (inc 20mm face) 190mm wide
    The Motherboard tray is a wopping 355mm long and ummm . . . opps forgot to record the height but same as the motherboard atleast.
    ATX specs are 305mm high by 244mm long, so there's over 100mm extra length on this tray.


    My what a lot of dust in here, I think I ust be the first person to open this case since it was built. see thoes finger wipes I did to check the dust thickness


    There's an achent soundblaster under there


    Pentium2 350mhz


    Couldn't resist


    And finally, no it's not a photoshop job just a realy bad camera

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    Re: Building a case from scratch?

    One final thing, a quick and dirty layout diagram to show my currnte thinking of the insides

    Not sure about the 140mm at the bottom, might jeust have a giant filtered hole instead or holes plural

    I love the upsidedown low PSU mounting as seen in the Antec P180/182 and CM 690
    the Top will be 4x140mm fans to suck all the riseing heat out, with the CPU tower cooler pointing upwards.
    Almost not rear venting (except PSU and graphics card and no front vents at all.
    I was thinking of leaveing quite a bit of clearance between the top of the motherboard and case top (unlike the p180 and CM690) so in future I have the possibility of dipping into water cooling and mounting radiators in the top of the case.
    Not sure on the HD orientation, was thinking of the power&connector pointing up and makeing up some form of padded rail system, so they drop in.
    2 structal rails/barces, to give the case rigidity andalow me to berak up the sides.
    instead of a single side plannel I was thinking of 3 or 4, with handels mounted on the upper side pannels for eaiser lifting.

    So what do people think of that as an idea for a case layout/air flow?

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    Re: Building a case from scratch?

    fan-overkill. No way that you'll need 6x140mm fans. I'm pretty happy with one 140mm, one 120mm fan and the CPU-HSF 100mm fan. I'm pretty sure that in this special case one or two barely audible fans are less noisy than six individually hardly audible fans.

    I also don't think that up to down is such a swell idea, as the expansion card lie horizontally. How about back to front and individual compartments?

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    Senior Member Hicks12's Avatar
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    Re: Building a case from scratch?

    i wouldnt recommend the top to bottom flow, its much harder for fans too suck up air from a small gap then a huge gap. My suggestion is move the hard drive bays under the 5.25" bays and put them in the 3.25" ones, shove the fans on the front of them.

    Keep 2 140mm(or 2x 120mm) fans at the top, at the back 1 or 2 would be fine, then shove a few on the back, the best way for airflow is too either have the equal amount of fans sucking in as sucking out e.g. 2 front 12cm fans and 2 rear 12cm fans or too have more sucking in as you have the standard gpu fan and cpu fan helping.

    Id also suggest putting the psu on some rubber feet too raise off the bottom which reduces noise and increases the efficiency of the cooling. Another thing you could do with the case fans is have 1 at the bottom front of the case(inside) and have another fan just on the support rail above the psu, this would mean the air from the bottom front channels down too that fan and then the fan sucks it up over the graphics card, would help keep the card much cooler.

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    Re: Building a case from scratch?

    Yep it's fan over kill alright
    actually thinking for removeing the 140mm from the bottom, a single 120mm under the hard drives to help cool them.

    As to expansion cards, I only have the one, that's the graphics card. I've thought about this, yes they do form shelves that in theroy block and trap air, but how is that any differnt in a normal case layout?
    The front fans are too far away to provide and real air movement between them and the only air escapeing in that area is from small rear vents but most of it is sucked up above the cards by the rear case fan and psu fan.

    I have been wondering about connecting an air duct to a fan at the bottom of the case so that the air is piped up and stright into the graphics card cooler, although the cooler fan might not be happy haveing extra air forced in.

    Looking at that design again I can see the dvd being a bit of a shelf too so I was wondering about mounting that vertically as well, so the tray ejects out of the top of the case.
    Also wodering about then cutting out a section of the dvd top and replaceing it with perspex so you can see the disk spinning inside (note not the whole top, I'd leave the top spinner/bareing in and a chunk over the optical head, don't want to watch disks destroy themselves or burn out my retinas.)

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    Re: Building a case from scratch?

    Intersing
    Quote Originally Posted by Hicks12 View Post
    i wouldnt recommend the top to bottom flow, its much harder for fans too suck up air from a small gap then a huge gap. My suggestion is move the hard drive bays under the 5.25" bays and put them in the 3.25" ones, shove the fans on the front of them.
    Umm Im not useing that case except from chopping it up for bits of metal and the motherboard tray.
    I'm considering building the whole thing frome scratch myself not modding an existing case.
    As to a small gap I'm considering some really big feet a good 20mm or so tall and ther will be a large gap to pull air in from as a good 80% of the bottom will be a big hole.

    Id also suggest putting the psu on some rubber feet too raise off the bottom which reduces noise and increases the efficiency of the cooling.
    Umm how would that help keep it cool?
    I was planning on makeing a rubber gasket to go around the base of the psu and the back to reduce any vibrations.
    I'm not planning Antec 900 but CM690 style here, a hole in the bottom of the case that the psu fan sits directly on, so air will get sucked up directly from outside the case then pushed stright out of the back none of the air inside the case will enter the PSU and visversa.

    Another thing you could do with the case fans is have 1 at the bottom front of the case(inside) and have another fan just on the support rail above the psu, this would mean the air from the bottom front channels down too that fan and then the fan sucks it up over the graphics card, would help keep the card much cooler.
    Now that's an idea I like will have some problems as the cooler I have on my 7900gs is basically the same as the one from the 7900gtx, with a fan in the middle that blows half the air out of the rear of the case and half in the other direction back into the case, so a fan behind the card would be fighting against the air coming out of the card.
    Maybe if I knocked up a fan duct from the front of the card to vent that air upwards . . . that's a plan.

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    Re: Building a case from scratch?

    havent got much time too answer in full but, i was refering too your sketch when moving the fans etc .

    And ignore the psu cool thing .

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    Re: Building a case from scratch?

    Ahh I see, I think.

    I think I will stick with the up/down cooling for now, or just stick with my current case.
    While my current case is my first real major mod and so doesn't look that pritty esp around the back (like I get to see that bit ) and the sound levels could be improved but it does work well cooling wise.

    I think my main drive atm is giveing my self something to do and a challange.

    Also this up/down air flow just seem to make sense to me, especially not having 2 or more fans trying to pull the same air in two diffrent directions.
    I'm thinking rear+top fan here as in the antec 900 or 180, granted thoes cases prove they work it just seems odd and useing brute force to fix a problem.

    The problem = removeing hot air from the case
    beacuse of teh shape and format of an ATX motherboard there's only really space for one rear 120mm fan.
    While you could increase the width of the case to put more in they are then sucking air from beside the motherboard and cpu not from around/over it
    So Stick the extra fans above the motherboard, once the PSU is moved below it there's plenty of space and access to the air around the MB, not forgetting hot air rises.
    But the downside is that the fans are pulling in differnt directions and will be disrupting the through flow from a tower cooler, so they rely on brute strength to suck as much as possible to overcome the short fall.

    So in theory, fans above only means you can possition 2 or 3 directly over the motherboard while still pulling in the same direction and not dissrupting each other.
    Added to that a tower cooler pointing up will feed into this pull without dissruption and hot air riseing should add to the overall flow.

    There are some dissadvantages I can see to this, noise.
    I've learnt from experience that a fan at the back of a case will always sound quiter than one at the side or front.
    Not exactly sure how much differnce top fans would be compaired two front or side.

    e.g. my current case has 3 fans at the edges (there are more but they are burried inside the case and that really reduces sound) 1 rear fan (normal placement, fan grill) 1 fan in the side pannel (bottom rear corner, fan grill) and 1 at the front (bottom, behind the vented face)
    Now side by side I have to have the rear and side fans tuned down to match the sound of my front fan but in the case I can run them faster before they sound as loud.

    So a fan mounted in the top will not be a quite as if it was mounted at the back, however should be quieter than on mounted in the front.

    Well that's the theory, added to this is the extra size sould reduce the volume more without haveing to add another 20mm to the width which would be needed for a 140mm rear fan
    And yes I did consider getting some of the big Antec 200mm fans used in the 900 and couple of thoes on top instead. but that's a bit extreme even for me

    Sorry for the semi rant there, just trying to get my theory across and clear.

    And ignore the psu cool thing .
    Is my brain being paranoid and arguementative or is my sarcasm sense broken?
    If you were being sarcastic then please explane, I am know to lissen to explaned reasoning.

    Oh and looking at that rough plan I think I lined the top fans up in the middle for the sake of neatness, they should be more towards the rear esp if I stick a dvd in front of them.

    I could probably get 6 HD's in the space I've left for them, that's really rough as I'm not yet decided how to fit them and still playing with ideas, so keep em coming.

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    Senior Member Hicks12's Avatar
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    Re: Building a case from scratch?

    well the psu wouldnt get cooler but stay around the same if it was on the ground, because the case can act like a heatsink by transfering the heat but so can the air aswell, just ignore that bit .

    I will draw up a thing in paint just too show roughly what i ment.

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