slipperyskip

Project Worklogs => Completed Projects => Topic started by: slipperyskip on January 03, 2016, 12:15:41 PM

Title: Project SkyVue - 2016
Post by: slipperyskip on January 03, 2016, 12:15:41 PM
(http://slipperyskip.com/18/001.jpeg)
This is a case mod project. The case being used is a Silverstone LC02 that the company donated to me back in 2007. It was initially involved in a project that got shelved because the motherboard wasn't ATX compliant. What I like most about it is that it is all-aluminum so it should be easy to work.


(http://slipperyskip.com/18/002.jpg)
The case came with Silverstone designed and branded riser cards and extensions so that PCIe cards could be installed in a "laid down" position.


(http://slipperyskip.com/18/003.jpg)
The motherboard was donated by Gigabyte. I really like their WIFI series of mini-ITX boards with its all-black color theme.

(http://slipperyskip.com/18/004.jpeg)

(http://slipperyskip.com/18/005.jpeg)
Here is the motherboard and graphics card installed in the case using the riser/extention parts.

(http://slipperyskip.com/18/006.jpeg)

(http://slipperyskip.com/18/007.jpeg)

(http://slipperyskip.com/18/008.jpeg)
Corsair's new low-profile mini-ITX AIO water cooling system.


(http://slipperyskip.com/18/009.jpeg)

(http://slipperyskip.com/18/010.jpeg)

(http://slipperyskip.com/18/011.jpg)
The case has to be modified to provide for the cooler exhaust vent.


(http://slipperyskip.com/18/012.jpg)

(http://slipperyskip.com/18/013.jpg)
Before cutting out the vent with a Dremel, a piece of aluminum bar stock has to be attached along the edge in order to strengthen the area. The case has a cut in an unfortunate place in order to attach a drive bay that will not be used in this project. I used a two-part epoxy for this.
 

(http://slipperyskip.com/18/014.jpg)

(http://slipperyskip.com/18/015.jpg)
The mounting system for the Corsair cooler shares three of the four motherboard mounting screws. The screws that came with the kit didn't fit the Silverstone built-in standoffs. Easily fixed by a trip to the local hardware store.


(http://slipperyskip.com/18/016.jpg)

(http://slipperyskip.com/18/017.jpg)
Cooler "dry fit" to check for proper vent location. The unit has a foam collar that fits tightly against the case interior in order to seal the exhaust.


(http://slipperyskip.com/18/018.jpg)

(http://slipperyskip.com/18/019.jpg)

(http://slipperyskip.com/18/020.jpg)

This project is being brought to you by:

(http://slipperyskip.com/18/corsairlogo.jpg)

(http://slipperyskip.com//17/376.jpg)

(http://slipperyskip.com/Silver2.jpg)

Thanks for looking!
Title: Re: Project SkyVue - 2016
Post by: slipperyskip on January 04, 2016, 03:26:00 PM
(http://slipperyskip.com/18/021.jpg)
Drilled out rivets and unfolded parts of the case. Flattened out the corners using C-clamps and wood planks.


(http://slipperyskip.com/18/022.jpg)
Taping up the case for Dremel work.


(http://slipperyskip.com/18/023.jpg)

(http://slipperyskip.com/18/024.jpg)

(http://slipperyskip.com/18/025.jpg)

(http://slipperyskip.com/18/026.jpg)

Thanks for looking.
Title: Re: Project SkyVue - 2016
Post by: slipperyskip on January 07, 2016, 02:49:56 PM
(http://slipperyskip.com/18/028.jpg)
Removed paint down to bare aluminum.

(http://slipperyskip.com/18/029.jpg)

(http://slipperyskip.com/18/031.jpg)
Cut a piece of 1/8" aircraft grade 7-ply birch plywood


(http://slipperyskip.com/18/033.jpg)
Glued it up using polyethylene adhesive.

(http://slipperyskip.com/18/034.jpg)

(http://slipperyskip.com/18/035.jpg)
Made two back panels out of 1/16" aircraft grade 5-ply birch plywood. Note difference in cooler vent hole size.


(http://slipperyskip.com/18/036.jpg)
The two back panels glued together with wood glue creates pocket for vent mesh.


(http://slipperyskip.com/18/037.jpg)
Cut vent mesh to size.

(http://slipperyskip.com/18/038.jpg)

(http://slipperyskip.com/18/039.jpg)

(http://slipperyskip.com/18/040.jpg)
Some dry fitting to check the progress. I'm calling this a bikini chassis because it's only just enough to get the job done.

(http://slipperyskip.com/18/041.jpg)

Thanks for looking!
Title: Re: Project SkyVue - 2016
Post by: slipperyskip on January 10, 2016, 03:03:45 PM
(http://slipperyskip.com/18/042.jpg)
Trimmed up a bit more of the case around the video card. Glued up the wood to the aluminum again using the polyethylene adhesive.

(http://slipperyskip.com/18/043.jpg)

(http://slipperyskip.com/18/044.jpg)

(http://slipperyskip.com/18/045.jpg)
A challenging step in this project is to splice an SFX power supply to a case that came with a Flex ATX power supply. I used as much of the contiguous original aluminum as possible for strength purposes.


(http://slipperyskip.com/18/046.jpg)
To fill in gaps, add a little strength, provide mounting points and the proper spacing I cut out these aluminum pieces. This is a dry fit. I'll glue these in next.


(http://slipperyskip.com/18/047.jpg)

(http://slipperyskip.com/18/048.jpg)
I made this collar/spacer that shifts the mounting point downward 3/8" to a place with more surrounding metal. The collar also defines the interior space that will be enclosed later.

(http://slipperyskip.com/18/049.jpg)

(http://slipperyskip.com/18/050.jpg)

(http://slipperyskip.com/18/051.jpg)

Thanks for looking!
Title: Re: Project SkyVue - 2016
Post by: slipperyskip on January 13, 2016, 01:46:17 PM
(http://slipperyskip.com/18/052.jpg)
Assembled to check for progress.

(http://slipperyskip.com/18/053.jpg)

(http://slipperyskip.com/18/054.jpg)
Cut a notch and modified my spacer/collar to help reduce the overall size.

(http://slipperyskip.com/18/055.jpg)

(http://slipperyskip.com/18/056.jpg)
Drilled out holes and attached a piece of 1/2" x 1/16" aluminum angle with #6-32 screws and nuts.

(http://slipperyskip.com/18/057.jpg)
This is not only to add strength but also provide a place to hide a portion of the PCIe cable that will stretch to the top of the case.

(http://slipperyskip.com/18/058.jpg)

(http://slipperyskip.com/18/059.jpg)
To attach the power supply I first made a wooden template. This defines the outer edges and the attachment holes.

(http://slipperyskip.com/18/060.jpg)
The Silverstone SFX power supply I'm using as a model (not the final unit to be used) has six attachment threaded holes. The SFX standard calls for three. I've also seen SFX units with four and five holes. I'm not exactly sure what brand or model is going into this yet so I'm preparing for the worst (best?!) case scenario.


(http://slipperyskip.com/18/061.jpg)
I made this aluminum power supply "surround" from the wooden template.

(http://slipperyskip.com/18/062.jpg)

(http://slipperyskip.com/18/063.jpg)

(http://slipperyskip.com/18/064.jpg)
The surround will be bonded to the original work to provide a solid metal attachment point for the power supply.

(http://slipperyskip.com/18/065.jpg)

(http://slipperyskip.com/18/066.jpg)

(http://slipperyskip.com/18/067.jpg)

Thanks for looking!
Title: Re: Project SkyVue - 2016
Post by: slipperyskip on January 15, 2016, 12:50:14 PM
(http://slipperyskip.com/18/068.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on January 18, 2016, 02:46:15 PM
(http://slipperyskip.com/18/078.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on January 21, 2016, 12:15:42 PM
(http://slipperyskip.com/18/088.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on January 23, 2016, 04:44:18 PM
(http://slipperyskip.com/18/104.jpg)

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It was about here when I tried to cut off the tip of my thumb.

Light duty work and photography.

(http://slipperyskip.com/18/117.jpg)

(http://slipperyskip.com/18/118.jpg)

(http://slipperyskip.com/18/119.jpg)

(http://slipperyskip.com/18/120.jpg)

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(http://slipperyskip.com/18/126.jpg)

(http://slipperyskip.com/18/127.jpg)

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(http://slipperyskip.com/18/131.jpg)

(http://slipperyskip.com/18/132.jpg)
Not in final project spec but I'll be testing this unit. It's nice to have something different to test the SFX physical standard.

 Thanks for looking!
Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 02, 2016, 01:43:40 PM
(http://slipperyskip.com/18/133.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 06, 2016, 09:49:09 AM
(http://slipperyskip.com/18/147.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 07, 2016, 02:50:40 PM
(http://slipperyskip.com/18/158.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 09, 2016, 05:25:59 PM
(http://slipperyskip.com/18/171.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 13, 2016, 02:24:02 PM
(http://slipperyskip.com/18/184.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 16, 2016, 03:17:57 PM
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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 17, 2016, 04:25:06 PM
(http://slipperyskip.com/18/218.jpg)

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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 20, 2016, 06:01:35 AM
(http://slipperyskip.com/18/231.jpg)

(http://slipperyskip.com/18/232.jpg)

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So it's 4AM and I'm working on this project. I'm feeling chatty so I thought I would go on about some of the design ideas in this project, especially the optical illusions.

My first job was working at Walt Disney World the summers of 1972 and 73. The first two summers they were open. Part of the extensive orientation was to equip us with fun facts and trivia to help amuse the guests. The leaves on the Swiss Family Treehouse were all hand painted and how many of them there were. I once knew. One area discussed was the role of the Disney Imagineers, their term for engineers/designers who were responsible for the optical illusions used at the park. The best example was the size of windows and outdoor fixtures on the second floor of buildings on Main Street. They were approx. 2/3 scale so as to give the illusion of greater height. Why build tall buildings when you can just make them look taller?

The Imagineers sparked my interest in engineering and motivated me to pursue that occupation. I have a lot of fun doing this modding thing and it's primarily due to the illusions I get to design and manipulate.

The above post is a prime example of this. It may seem mundane but I consider it clever enough to inflict it on to you.

The crack line (as I call it) is the where the exterior case separates from the internal chassis. It's how you open it up. It can be the most challenging design task in a scratch build. It is much easier to build something clever if you don't have to open it up and actually work on internal components. My philosophy is to make it possible but not necessarily easy to access the components.

Once the crack line is established then the job becomes hiding it. Tight tolerances of course but there are other things. For this project, the decorative element running across the top and down the front terminates at the crack line around the base. Instead of trying (and failing) to make all those tolerances work I have decided to plunge the element below the visible plane. The resulting illusion is that element ends perfectly at "street level" when in fact it is a bit of a mess just below the surface.

(http://slipperyskip.com/18/238.jpg)

Even just a slightly imperfect junction here would point out the crack line that runs through it.

Another illusion is a classic that all women know and some use. Vertical lines are slimming. I post this following render to illustrate that the center box is, in my opinion, a fatty. What I have done is split the box and added vertical lines to hopefully give the illusion of a tight, slender middle box.

(http://slipperyskip.com/18/243.jpg)

Another more complex illusion that harkens back to the Imagineers is the widths of the ledges. Starting from the very top split section, each succeeding ledge is smaller than the one above it. The top "ledge" is 3/4" wide while the bottom ledge just above the base is 3/8". This gives the illusion of a much larger size and depth. The wife saw the project yesterday and commented that it looked taller than she imagined. It's really not that tall. It only looks it.

The final illusion is the easy one. Black makes things disappear. That is why the center section is painted black so that spaces between the aluminum trim appear to reach deep into the case and ventilate it. For the record, the black paint also shims the aluminum trim. I control it by adding layers of paint to achieve a snug fit.

That's it for this edition of "How Clever Am I?" See you next time. :)

Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 22, 2016, 02:49:16 PM
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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on February 29, 2016, 12:06:36 PM
(http://slipperyskip.com/18/265.jpg)
I'm currently designing/building a video card backplate to help hide the PCIe cable

(http://slipperyskip.com/18/266.jpg)

(http://slipperyskip.com/18/267.jpg)

(http://slipperyskip.com/18/268.jpg)

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Raw Sapele sanded to 220 and a teak oil finish test piece.

This post brought to you by a new sponsor:

(http://slipperyskip.com//17/371.jpg)

(http://slipperyskip.com/18/273.jpg)

(http://slipperyskip.com/18/274.jpg)
Title: Re: Project SkyVue - 2016
Post by: slipperyskip on March 04, 2016, 09:44:16 AM
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Title: Re: Project SkyVue - 2016
Post by: slipperyskip on March 06, 2016, 10:36:26 AM
Sapele wood with a teak oil finish and polished T6511 aluminum trim.

(http://slipperyskip.com/18/283.jpg)

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(http://slipperyskip.com/18/298.jpg)

List of donated equipment:
(http://slipperyskip.com/18/299.jpg)

A huge thanks to my friends at:

(http://slipperyskip.com//17/376.jpg)

(http://slipperyskip.com/18/corsairlogo.jpg)

(http://slipperyskip.com/Silver2.jpg)

(http://slipperyskip.com//17/371.jpg)

Thanks for looking. It has been great fun!
Title: Re: Project SkyVue - 2016
Post by: slipperyskip on March 25, 2016, 12:17:56 PM
(http://slipperyskip.com/18/301.jpg)

(http://slipperyskip.com/18/302.jpg)