Project: RE-Define XL (with 2 x 480 rads)

[wissel]

Project: RE-Define XL Update 30/10/12 - Water Loop Finished

I couldn't think of a good name so this will have to do.

I recently built a new PC and I’m just not happy with it so a few things are going to be changing soon. One thing I really don’t like is the general layout of the PC and I cant find a case that I do like the layout of so I thought I’d mod one and do this build log.

Here is the spec of my current PC:

Fractal Define XL
Corsair AX 750
Asus Sabertooth X79
I7 3820
32 GB G.Skill RipJawsZ 2133MHz
128 GB Crucial M4
500GB WD Caviar Black (x2)
Gainward Phantom GTX 670
GT 620
LG IPS 22” Monitor (x3)
LG 22” Monitor (x1)
Mackie u402 Firewire Audio
Behringer MS16 Speakers

Water Cooling:

XSPC Raystorm CPU Block
XSPC Raystorm GPU Block
XSPC RX 240 Rad
XSPC EX 360 Rad
EK Multi Tube Res

Here’s a picture of what it currently looks like:

I like most of the components in my build but will make the following changes:

Add another Gainward Phantom GTX 670
Replace the 2 500GB drives with a 1TB Caviar Black and a 2TB Caviar Green
Add XSPC GTX 670 water blocks
Add the Koolance motherboard blocks for the Sabertooth
Add 2x Hardware Labs Black ICE Radiator SR1 480 (at 517mm long they fit perfect)
Get a new Define XL case (the existing case & water cooling bits will house my other PC)
Either Bitspower or Koolance fittings.

I’ve been at the beech for the last few days (love living in Cornwall) and have been designing all the case mods in a sketch pad. My free hand looks like a 2 year olds (no offence to 2 year olds) so I’m not going to post them here so I only have a quick mock up to show what I would like to achieve. I will post detailed pics of all the mods once I’ve drawn them.

Here’s the concept:

… and a quick sketch of what the side panel will look like:

That’s all for now, will hopefully get the other drawing online in the next few days.

PS I’m going to have to order several panels cut/milled and powder coated to my specs. I cant find anywhere local to get these done so if anyone can recommend somewhere that’s good I’d really appreciate it (either in thread or message me if it’s a company that shouldn’t be mentioned on here)

 

[panyan]

the mockup looks like this could be an incredible build!

considering you want to do some major chassis changes, perhaps look for a different case? perhaps one with a horizontal layout already?

 

[Muel]

This plan has the potential to be one of the best builds of 2012 IMO... God speed.

And paint it white.

 

[wissel]

the mockup looks like this could be an incredible build!

considering you want to do some major chassis changes, perhaps look for a different case? perhaps one with a horizontal layout already?

Cheers for the comments.

With regard to the case I really like the way the Define XL looks from the outside - besides, swapping the layout isn't that complicated a job.

This plan has the potential to be one of the best builds of 2012 IMO... God speed.

And paint it white.

Again, cheers for the comments (but it will be black I'm afraid )

 

[Muel]

No, I think you misunderstood.

Paint it white.

Out of interest, how you you propose to plug things into the IO panel when it's going to be covered up by radiators? (If I'm reading the picture correctly and you're going to rotate the board by 90D).

 

[wissel]

I've started drawing the panels so I can get a few quotes this morning, hoping to have a few more finished today but here are the new front and back panel sketches.

Mock up of front and back panel fitted to case.

 

[Tealc]

Should be interesting.

 

[piggin]

PS I’m going to have to order several panels cut/milled and powder coated to my specs. I cant find anywhere local to get these done so if anyone can recommend somewhere that’s good I’d really appreciate it (either in thread or message me if it’s a company that shouldn’t be mentioned on here)

You need to contact Pulse modding

I love the idea of fitting more than one 480 into a case but you do need a very big case to fit it all in

 

[wissel]

No, I think you misunderstood.

Paint it white.

Out of interest, how you you propose to plug things into the IO panel when it's going to be covered up by radiators? (If I'm reading the picture correctly and you're going to rotate the board by 90D).

The rads will be to the front on the case (looking side on) with the IO panel behind

You need to contact Pulse modding

I love the idea of fitting more than one 480 into a case but you do need a very big case to fit it all in

Cheers for that piggin - I'll send them an email once all the drawings are done.

Your right about the size needed - the define XL is a very big case and I only have a few mm in either direction to play with

 

[wissel]

I've sent a few drawings off for quotes now and also changed the back panel design a little.

Here's a mock up of the internal panels being quoted for.

Its not to scale but gives a general idea.

 

[johnny sublime]

looks like an epic idea man i will be watching

 

[wissel]

Okay quick update:

There is no update

I sent of for quotes from two companies last Friday and so far not had a price of either of them.

If anyone knows of another company that can cut and mill a few panels I would really appreciate it as want to get them ordered ASAP.

Thanks in advance.

 

[snaggster]

Okay quick update:

There is no update

I sent of for quotes companies I found on the bay last Friday and so far not had a price of either of them.

Now I'm thinking if they cant get a 5 minute quote out within a week how long would it take to actually make a panel?

If anyone knows of another company that can cut and mill a few panels I would really appreciate it as want to get them ordered ASAP.

Thanks in advance.

It may not seem it, but it is quite a big job. To give you a rough idea of cost, we charge £125 an hour for cnc machining. With programming and the operation time you will be looking at min 3 hours!! And that is if you can find an engineering company that would be happy to take a one off job like this on. Most are only interested in large or patch work.

For what your wanting, you would be much better of looking for a company that has a water jet or lazer cutting machine. Due to the fact there are no tooling costs, and the programming being more simple 2D. The cost will be a lot less. I'm guessing about £50 an hour.

 

[wissel]

It may not seem it, but it is quite a big job. To give you a rough idea of cost, we charge £125 an hour for cnc machining. With programming and the operation time you will be looking at min 3 hours!! And that is if you can find an engineering company that would be happy to take a one off job like this on. Most are only interested in large or patch work.

For what your wanting, you would be much better of looking for a company that has a water jet or lazer cutting machine. Due to the fact there are no tooling costs, and the programming being more simple 2D. The cost will be a lot less. I'm guessing about £50 an hour.

To be honest I'd be happy to buy the metal 'cut to size' mail order, make all the cut out's at home myself then send them to someone to just fold the edges up (as drawings above). I can paint them here once they are back.

Do you or anyone else know a company that could just do the folds for me?

 

[snaggster]

To be honest I'd be happy to buy the metal 'cut to size' mail order, make all the cut out's at home myself then send them to someone to just fold the edges up (as drawings above). I can paint them here once they are back.

Do you or anyone else know a company that could just do the folds for me?

You will have several company's that can do that for you, on your door step! Have a drive round your local industrial estate. You will be surprised at the amount of small engineering firms. Many of them will be happy to do it for a couple of beer tokens.

 

[wissel]

You will have several company's that can do that for you, on your door step! Have a drive round your local industrial estate. You will be surprised at the amount of small engineering firms. Many of them will be happy to do it for a couple of beer tokens.

That a good idea

I'll have a float about tomorrow, cheers.

 

[wissel]

Well I spent 4 hours today driving around trying to find somewhere that could make my panels for me, eventually found a great little company that will fabricate the 5 panels I need to get going in 2mm aluminium at a great price.

This is what they are making:

I wont post the exact panel drawings yet as I'm waiting for a new Define XL to be delivered and want to check a couple of things before I submit my order.

Should hopefully have them here by the end of next week

 

[wissel]

Ok a small update as a lot of the parts have now arrived.

The new Define XL case, 2x Hardware Labs SR1 480's, a WD Caviar Black 1TB, another GTX 670 and a Lamptron FC9 Fan Controller.

... along with my new favourite toy, the Dremel 4000 - honestly it is fantastic, but not as fantastic as....

...Haribo
Now I feel special
(the mrs just said I am )


So first the case goes on a crash diet

Sides and cage removed

...then fans and other plastics removed

...then gutted. Probably should have moved my mouse mat first

Now to see if the rad will fit

....bugger it don't (but will with just a little bit of Dremeling)

Now for the Fan Controller

I'm really surprised by how high quality the Lamptron FC9 is. I almost feel guilty for stripping it down so it works how shown in the OP.

It comes apart really easy and will work great I think.

All the panels are on order and will be with me next week so that's it for now apart from this quick spoiler

This is the fan grill design being cut into the panels.

 

[JamesM]

subscribed!

 

[wissel]

The new panels won't be with me until next Thursday now (taking a few extra days at the laser cutters) so I thought I'd get on with a job that I've been dreading - wiring.

I decided it would be a good idea to completely remake most of the cables in this build so they all match and are the right length etc. After spending half a day on this job I'm not so sure it was a good idea as its a pain in the arse.

Sure it will all be worth it in the end though

I've been ordering little bits and bobs for this job for a while now, here's a bit of a selection of them:

I've never touched the cables in a PC before, never soldered wires and never used heatshrink so did a little test piece first:

That went well so decided to start on the fan wires. I want all 4 fans on each 480 rad running of a single header on the fan controller

So fitted the fans and stripped the wires back

The blue wire wont be used so I cut this back out of the way

and started joining the new wires and heatshrinking. When I ordered the wire green was out of stock so using red as the green wire

Then added the braid up to the point of the next wires, melted a section to join the next wire, soldered and heat shrinked again

clamping the braid back made the job easier, as did pulling the wire back from the edge of the fans

repeated a few times

and its done

I finished the new cable with black paracord to match the other new wires and added the 3 pin connector to the end.

Then the moment of truth - see if it works

BOOM! (in a good way) it works great!

One set of wires done, only a few million more to do.

I'm going to spend the weekend getting most of the wires finished and making the LED's up, the final water cooling parts will be here Tuesday (hopefully) so will post another update once the motherboard is bench fitted.