Project: Water Cooled Apple Cube Case

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24 Mar 2013
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Background

This is my first posting on Overclockers, though I have been a lurker for some time and have done a number of mod.s

I wanted to post on here, because I hope this project has a wider appeal than some of my earlier mod.s to Apple cases and also because it is something that I may well need help and advice on as the mod progresses.

I have liked the G4 Cube for quite some time and have done a few mod.s on them, the last couple used the original Cube heatsink to cool them and worked well.

For those unfamiliar with the original Apple Cube case, this is it:

g4cube1.jpg

cubeopen.jpg


The format was an 8 inch Cube with a removable core inside a perspex case, a touch switch, a very neat handle latching mechanism and a huge internal passive heatsink.

It was hugely expensive at the time and was considered by many to be one of Apples greatest flops, but it was stunning in terms of design.

That design has inspired many mod.s to house ITX boards in recent years. One of my own favourites of the ones I have done up until now is this one:

pc260244.jpg


As I run a laser cutting business, in this mod I explored a lot of what could be done to modify the externals and the whole thing top loaded into a perspex Cube stand and re-used the original passive heatsink.

Watercooled Cube



The mod I am starting now is something different though and will pose a great challenge - as I want to fit a water cooling loop into the original Cube format.

In many ways, this build is only going ahead because I had a lot of the components sitting here already. Bits being re-used from other builds are:

Zotac Z77 wifi board
Corsair RAM,
Corsair H80,
160W PicoPSU,
mSATA drive,
Old Cube bits.

New parts:
i7 3770k

I'll admit this is a bit of a silly power crazed build. Having done a Cube with an i5 2500K I wanted to up the Geekbench scores and see whether the unused H80 I had could be used in a Cube and could keep an i7 3770k cool with a mild overclock.

I looked around for any existing water cooled cubes and all I could find was this single photo:

okatuwatercubef.jpg


I couldn't find anything with the Cube boxed up, and I gather this was a mod of 2004 from Boris Jotic who was water cooling his original upgraded Cube.

What I want to do though is have the loop inside the case and I don't think that has been attempted or achieved up until now - if anyone has, please let me know!

The build

First things to do were to check the Itx board and H80 block would fit on the "thin" side of the Cube case (Cube internals are asymmetrical and challenging….):

p2251641.jpg


So, the dummy board would fit, and there is about 2mm of clearance between the integrated block/pump and the central handle latch mechanism.

Next check is to see how the radiator might mount in the case. I came up with this:

p2251644.jpg


p2251648.jpg


What you see here is the radiator mounted to the original CD drive holder and, to the right of the second picture a 120mm fan that sits where the original Cube hard disk would have been. This holder makes a nice frame to hold the radiator and fan combo.

As a first fit I was happy that this would be a good place for rad mounting and with a bit of luck just the one 120 fan might do the job if I can get a good air flow in from top and bottom of the Cube. If I am not so lucky I can put another 120 fan on the outside at the back of the Cube and make it removeable.

As the radiator would be against a solid wall inside the Mac inner case, the next thing needed is to cut it:

p2251649.jpg


No laser cutting here, just good old dremeling - this case eats dremel disks!!!

 The discolouring is as this particular old case originally had my old Mac Mini in a Cube mod inside it that my wife has had for a number of years. It was re-sprayed white at one stage and after being knocked about by me it now needs stripping and painting again.

 This great big hole is for the radiator to expel heat out the back of the Cube - the plan being that from the front view the Cube looks pretty much normal.

The same Cube case had a cut down casing and was used on its side. This case will probably not be the final outer case, but I cut it up for practice too:

p2261663.jpg


This part did have the hole laser cut in it, but surprisingly it turned out the acrylic used by Apple was of a fairly poor quality (in my opinion). This type of acrylic is a bit unpleasant to laser cut as it is quite soft and the edges instead of taking on the lovely flame polished effect that is acheved with good quality acrylic, it bubbled at the edges and was quite smelly to cut. I'll have to get out the wet and dry and my polishes and work on the cut edge to make it more presentable.

In a real Cube the drive cage is normally front mounted and I want to move it to the back so I needed to make some more changes to the inner case and the can that surrounds it.

The logo for the Cube touchswitch is towards the rear of the acrylic case, and the actual switch is located to be above the motherboard area on the original Cube. That configuration does not work for me though as I really do not want the switch above the mobo as space there is tight and I'd prefer it above the radiator where there is some space.

This combination of factors and my rear facing radiator meant I needed to effectively spin the Cube, re-locate the switch on the inner Cube cage and then cut a new hole for it on the outer part. 

So the next job was cutting another hole for the touch switch on the inner cage and making some fixings for it -using my favourite thing of the moment rivet nuts.

p2261682.jpg


Here, the new hole is at the top.

And I then needed to do the same thing to the metal can part:

p2261668.jpg



The hole was cut using a hole saw and turned out better than I had hoped (one slip costs a lot of time!).

Next job to cut the tubes from the H80 - as there was no way it would fit with the long pipes - and drained the fluid.

p3011706.jpg


The pipes have an ID of 6mm and an OD of 8mm, so the plan is to rejoin the loop with hose of the right dimensions and lengths. This is about where I am and my current challenges are: (1) find a way to make the pipes turn in the right places without kinking - so have some springs and guides on order. (2) Find a way to get the loop closed again without it being full of air.

I have done some experimenting to see how I can get the loop closed again and so far it is frustrating. If all else fails I may have to resort to an external reservoir mounted behind the perspex case, but in the meantime I am trying: loop filling under water; trying to remove air and inject water with syringes. Both have been very frustrating.

The next try will be to put a temporary extra Laing DDC with a pump top reservoir in the loop and run the loop until I get all air into the reservoir and then try and do a tube swap underwater.

I'll post more as this project gradually comes together. I'm currently waiting my antikink springs and tube directors from OC UK as well as some 6mm G1/4 barbs to try out my theories with the Laing pump combo.

We shall see...In the meantime any suggestions as to how to avoid my fall back of an external tube reservoir mounted to the Cube back are greatly appreciated!
 
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Thanks for that, I haven't seen that tiny Bitspower res before - that looks like a cool little item and if I can't get the air out and close the H80 loop again it is now definitely my favourite.
 
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Short update.

After doing a bit of browsing I decided to ditch the Corsair radiator in favour of the Alphacool NexXxoS XT45 Full Copper120mm.

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The reason I chose this rad and am excited about this as a possibility is the 6 possible connections which in the restricted confines of the Apple Cube case will make things a lot easier. This should make getting air out of the loop simpler as I can connect up the closed loop and use the extra plugs to fill the block and then the radiator and then expel air from it and do a final fill before s*crewing in the two top end plugs.

Also buying a couple of Phobya 15mm thick 120mm fans that with this rad will just fit in the Cube design to give me a fully enclosed system.

The parts should be with me middle of next week.
 
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It's the Zotac Z77 wifi board. I have it already from a previous build. Any overclock will be limited anyway by the picopsu, but it'll be a fun experiment.

I tested out the system in a different custom loop with my 160w pico and with a mild overclock to 4GHz under turboboost and when stress testing for an hour it was stable and the peak power draw from the mains was 120W (idle around 40W). This though was just a quick attempt and used an arbitrary Vcore of 1.2v
 
Thanks for the comments.

Next stage will be to do a couple of cuts and then measure up for some more internal support panels.

I have decided that the orignal Cube handle and locking mechanism is not going to stay as it takes up a lot of room and restricts airflow, so I have taken those out but am adding some more rigidity back in to keep the Cube integrity.

Also by taking out the centre handle mechanism I think I can win enough extra room underneath the motherboard (out of the air flow) to install a small slot load drive.
 
Keeping this build quiet and within the power limits of the pico psu are two of the most important parts of this build, as well as seeing if it can cope with a mildly overclocked 3770k.

As part of this I am trying to test everything for power consumption/noise before it goes in to the Cube.

Just been test running the Corsair pump and Alphacool radiator combination, along with the two Phobya fans hooked up to a simple Asetek fan controller (literally about £3 inc. postage).

Noise from the fans at full tilt is reassuringly loud with a good through breeze, but when I use the controller it can be turned down to something less than audible.

Power draw at the wall from the combination of pump, and two fans is 14w (inc the draw from the ATX PSU itself that I am testing them on) at max settings and goes down to around 9 or 10 at lower speeds. Disconnecting the fans and pump and measuring just the draw from the PSU with fan shows that as taking about 5 watts - so in reality my fans and pump combo is taking a max of about 9W.

Seems okay.

The only other power consumption apart from main board and processor will be by myToshiba SSD (that I think is supposed to be an incredibly small 1.5W) and a slot loader that supposedly will run from a single USB input and therefore about 2.5W max.


In theory then I should have a maximum of up to 130W allowable for the onboard consumption of CPU, board and RAM for any overclock experiments....

So far so good.
 
So, a bit of an update today.

The aluminium rivetnuts arrived and so did a aluminium plate I had cut for the Cube.

So it was now time to get the files and dremel out again and do a bit more fitting up.

These are the rivetnuts for the new hanging system so I can get rid of the handle assembly:

img0248mq.jpg


Tip: if you have a cheap hand operated rivet tool M6 rivet nuts in aluminium are about the limit that I think you can mount properly!

Still, this open style of rivet nut will flush mount and give a really strong thread. First I had to open up the holes in the inner cage a little to take the rivet.

img0247gs.jpg




Then they went in fine

img0251np.jpg


This is the result:

img0246klc.jpg


img0245vb.jpg


Opening up the holes in the perspex and also a little in the top plate for the outer case meant the Cube will then be able to be secured in the case using some cap screws.

img0257sf.jpg


img0259jdw.jpg


img0256rw.jpg


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The aluminium laser cut turned out well.

img0243zl.jpg


and here you can also see how I have cut out the handle section (I'll replace this bit later with a more open mesh).

img0241vt.jpg


img0258c.jpg


So, this is where it is right now. Still working things out and fitting them up but it is coming together.

By the way, the two holes in the bottom plate are there to allow access to the two end caps at the bottom of the rad. If I find the loop needs more bleeding then I have easy access without having to take the build apart after it is finished. I will of course be doing a LOT more tidying to the various plates etc and adding some more laser cut pieces to finish things off nicely.
 
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Thought there was someone else doing a watercooled cube build for a minute then!

Hey Nick. No it is me! Most of my stuff these days is pure case mod.s and I have had a few people telling me they had heard of the Laser Hive from here.....so I thought it was time I started contributing to what is obviously a very active and inventive community.

:)
 
Just bought another Cube.

I couldn't resist it as I am needing to drive down that way soon for a family celebration so I can call in and collect it on the way.

I have modified my backplate design a little and that should be with me in the next week or so and will also be the basis for a new laser hive product line in a short while.

Basically I have made a complete backplate outline which, though I am cutting it for my own mobo pattern, I will easily be able to adapt for a standard ATX rectangular IO pattern. That new plate will then be bondable to the original back so it can be blended in to the original plate and allow the user to either keep the original handle mechanism (or get rid of it like I am doing) and to either keep the original small holes on the "wide" side of the cube or get rid of them. If the user wants to get rid of them it will then be an easy conversion to add a wider (more open) mesh for higher airflow if wanted - which is what I'll be doing to mine.

Basically the design frames the relevant parts of the backplate (top section, bottom section, handle) and the frame sides can hide any radical metal cuts and provide a support ledge for inserts to be dropped in behind the frame. So that as much of the original back can be retained or cut out as needed.

Because the outline will match the original Cube back outline it will just take a little filler, a quick sand and then a spray over to disguise the fact that there is a plate there at all.

This will be a new design to add to my website and it will be able to be ordered with custom re-positioning of the rectangular ATX IO to wherever the modder wants to put it - all I will need to ask for customising is the relative position of the bottom left corner of the ATX shield.


It won't be a full conversion kit (there are too many different ways of Cube modding to be able to do that). But it will let people have an easy way to tidy up their own backplate, it will add a few more millimetres of wiggle room front to back for PicoPSUs and it will give choice and an easy way to customise the air paths by opening new ones up or closing some off. I am aiming at a price point of just £18 for the plate to retail to the customer and it will be a special order item because of the need for the plate to have the ATX shield in the place of user choice (and also to account for either full height or half height ITX shields).
 
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Firstly, can't see the link, and it has a certain disallowed site in the link.

Secondly, I don't really get what you mean, is the backplate the bottom part?

Apologies I didn't realise about disallowed sites - have removed that link to the auction site.

Yes, for want of a better word by backplate I meant the bottom part of the Cube which includes all the IO.

I will post a jpeg tomorrow to illustrate this conversion piece a bit better.
 
I am still waiting for a few bits and pieces to arrive before continuing the Cube build.

In the meantime though I thought you might be interested in the fact that I am starting a companion mod. which will sit well with the Cube when it is finished.

There were reports of the iPad Retina display being hacked to be used as a stand alone monitor and a company in the Czech Republic are making adaptors for it....so I have decided to be an early adopter!

In theory the interface board should give an easy way of hooking all this up so I am going to make my own case for the adapter and display. It'll be in the style of the old Studio displays that Apple made, but adapted so I can cut it from flat sheets.

Here is the link to the adapter. It is not cheap at $99, but then again promises to be a good quality item and with new iPad retina displays on eBay for £50 and 15" Apple Studio Displays being able to be picked up for £15-£20 it will still be an affordable and striking little piece of kit (I hope) when completed.

I'll let you know how I get on!
 
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Here is a link to a youTube video just uploaded.

http://youtu.be/Gn_FbjipYfA

Today I worked out the length and connectors for the cooling in the case and hooked that all up.

The radiator and push pull fans are shown here fixed by the drive braket and the centre bracket. Here the system is inverted and filled and running. At first there was a lot of air in the loop and the pump very noisy, air is easy to get out of this loop though and a few top ups later the pump is running very quiet.

Fans here are hooked up to the corsair block and running full speed. Even so, they are not too noisy. The inner fan is soft mounted and the outer is hard mounted to the case parts. I might see if I can change the outer mount to a soft one too as this fan produces noticeably more noise.
 
Had some time today to progress a little further.

I'll post some pic.s tomorrow hopefully, but the internals are now almost mapped out.

I had been wondering how best to secure the mobo in the cube core - as the corner struts unhelpfully make it awkward to fix a tray. Today though I bit the bullet and made a support that joins the aluminium handle support rails to each other (to give it some extra strength and resist against twisting now that the heatsink has gone) and also fixed some threaded inserts into that support to take standoffs that will attach to the top of the mobo. In this way, instead of the usual support from underneath it is suspended from above. This extra support piece and the mobo fixing means I can build everything up without having the top or bottom of the cube in place.

Also wired my push pull fans into a single fan plug and then mounted the fan controller board to be at the bottom rear of the cube to make fan speed adjustments an easy step.

Last thing today was to re-wire the Corsair H80 block so it will draw it's power from the CPU fan header. I know the pump only uses 4W and as I am not using it to actually feed power to the radiator fans this convenient method saves a lot of messy wiring. Just plug the short lead in and it's done.

Wiring is one thing I am trying to be really neat with on this one and my aim is not to have to attach a flying molex trail from the pico PSU. SO my solutions to this are:
1. The two fans will take their power from the fan controller and that will take 12v directly from where the mains adaptor comes in;
2. The Corsair block powered from a fan header.
3. (And I think this should work) for my 500GB SSD the power draw is max of 2W. As the SATA data plug is right next to a USB 2.0 header I am intending to use just the power from a dual USB header into a SATA power connector for a minimal routing of 5v and GND power to my SATA drive. I have never seen anyone do this, but I presume that as I have seen external USB devices use a power only connection from a USB port that there is no reason why I shouldn't be able to do that internally.

By doing these three things I can reduce the connectors going to the pico psu down to just the CPU power plug.
 
Latest pic.s

This pic shows the core of the cube without the bottom plate. Here you can see the three plates I made up that hold the core parts together.

p3281781.jpg


First plate at the top of the shot is the metal plate that holds the outside fan and is bolted to the original drive carrier.

The second plate is a 5mm black perspex plate that fixes to one side of the original handle guide / Heatsink retaining pieces

and the third plate fixes to the other side of the same pieces.

Here is a closer shot of the first piece:

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and the second piece:

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And in the shot below you can see that the third piece is also used to suspend the motherboard via standoffs:

img0286fz.jpg


In this one you can see looking from the front plate down into the cube that the central area I have tried to keep as clear of clutter as I can - the water pipes have to go here and this is also the area that the fans will draw their air from.

Here is a side view showing how the SSD will fit.

If you look closely you can see the SATA power to USB power cable I made up.

p3281783.jpg
 
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Thanks for the positive comments guys.

I love this tiny format and I really believe that these days the case is becoming more and more practical. The challenge is trying to squeeze more and more (quiet) performance out of these 8 inch squares.

Can't wait to see what Haswell brings to the ITX format.
 
Sorry not been updated for a while.

Here are a few shots from just now.

ijib.jpg


This one shows the latest version of the back which I have laser cut in house from matt black acrylic. I am bonding the acrylic to the original base, which I have given a quick spray of satin black to see if I like the colour.

The extra holes in the back panel are for a power inlet and outlet at 12v, the adjustment knob of the small fan controller and for an extra USB port.

The 12v outlet is intended for my small "retina" display that I am making up, and the USB port can of course be used for a number of things, but internally it is connected to two of the 5v sources on a USB header so that it can provide higher power - such as for DVD recorder and also to give more possibility to use an original set of Cube speakers.

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I'm using JB weld to bond the parts together and when it is set I'll add more to smooth the join and then sand back, mask off the acrylic panel and spray the sides again. I have a compressible adhesive strip coming which if it looks okay I'll use to replace the original type of spongy trim strips the Cube had. I am hoping that that strip will provide a nice seal between the Cube base and the inner can (and also conceal any messiness where the panels join!).

So the current plan is for the Cube inner to be satin black....
 
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