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Case Modding Part One


Date
: 01/17/01 – 05:22:49 PM

Author
:

Category
: Misc

Introduction

Welcome all of you to-be case modders. This article will be an insight on how to, and how not to mod a seemingly healthy computer case.

I should start off however, by mentioning that I am not an art kind of guy. I do lots of graphics on computers, but could not paint a straight line if you paid me. So therefore this article will also be geared towards the artistically challenged. (you can email me about an artistically challenged parking sticker, which I will give away for free, so that you can park anywhere you like).

The victim …

First things first. I am not writing this article for the financially challenged. Remember that if you want to do something, you have to do it right the first time. Unlike me.

I have a beautiful AOpen HX08 Full tower server case, with a 300 watt power supply and more drive bays than you would know what to do with. This case BEGS to be modded!

Oh Yeah!

The plan …

The first thing you want to do before you start Dremeling away, is schematics! Whether it is a hand drawn picture by your 2 year old brother, or one done by a professional draftsman, you really should have one. On my schematics (hand drawn by a 2 year old), I decided to add a few fans(dont care much for peltiers and water coolers.yet)Where? (The following are my preferences but should give you a general idea)

1. A 12cm (yes we use the metric system) fan sucking air in the case, mounted in the front.

2. 2, 9.2 cm fans mounted on the side, blowing air on the CPU and Video card.

3. An 8cm fan as a blowhole on top.

4. 2, 8cm fans blowing air out the top/back of the case (above the PSU).

5. Maybe more fans inside :P

Black circles are fans…

So now that I have a general schematic, I can begin a more advanced level of planning.

This stage of the modding fiasco is a little more difficult. This involves drawing the layout of the fans, the cuts to be made, the areas for the fan screws, and the areas to be painted (if you choose to do so).

I am not a draftsman, and therefore drawing the fan layouts perfectly perpendicular to the ground is not easy for me. First off, the corners on my superb case J are rounded.not good for exact millimeter measuring. Nevertheless, find yourself a good, looooong straightedge, and begin measuring the case.

For my case, the top is 7.75 inches wide (I know I said metric but its too late now), and I dont care how long it is.why? To place the blow hole It is not a matter of centering the fan vertically, just horizontally. Make sure that there is nothing below that area of the blow hole that might obstruct the air passagewayor even the fan itself! See if you can find the center of the case (horizontally) and make a centre punchwhats that you say? No centre punch? Use a hammer LIGHTLY and a Phillips head screwdriver, and LIGHTLY tap the centre of the top panel. All we need is to be able to see it!!! You could mark it with a pencil but they can rub off, and are not as exactunless you do it incorrectly.

Got the centre? Good, now with the straight edge I measure 3.9cm out in each direction (horizontally), and make a little pencil mark(the other 1 millimeter on each side will be filed to smooth the edges). Now I have the extremities of the fan marked. I can use the straight edge to vertically draw two lines for the edges of the fan. Use the same method to mark the top extremities of the fan and BINGO. JUST to be sure, you can start from the centre punch and draw two lines at a 45 degree angle and the lines should meet the edges that you have already marked.

All done? Good. Use that method to mark the fans holes on the side panel also. In my case (get it) I used two fans on the side panel, and therefore had to make sure that they were spaced out evenly so that they do not overlap (on the drawingthe actual fans can not be in the same place at the same time.Stephen Hawking, or Einstein or someone). All done? NO? If you have trouble ask someone to HELP YOU. I know you arrogant men are usually afraid to ask for any helpfrom eldersbut by gum you will read later on that if I did not ask I would be screwed!!!

Picture kindly given to us by Virtual Hideout.

If for some reason you have finished the layout, and it is off, by either a millimeter, or a degree, I suggest you start over. The brain teaches itself motor skills through practiceso PRACTICE. DO NOT COMPROMISE! Only the best will do for your kick ass mod!

Got all the layouts done? And punched out the areas for the fan screws? If not then do it. Remember not to have the screw holes off by more than 1 millimeter, or 1 degree!!! Do not compromise!

Let’s get busy …

Now comes an interesting decision. Do I use a Dremel, do I use a drill (corded), my bare hands, or a jig saw to cut out these holes / windows. The choice is up to you, but I suggest using a drill press at any metal fab shop. What did I just say? Thats right, I ASKED my father for some help and he suggested Mr. So and so, who is a family friend who knows a guy who owns / operates a metal fabrication shop. Heck all you need is a drill press, and 3 drill bits. 3 for an 8cm fan, 3.5 for a 9.2cm fan, and a 4 bit for the mother 12cm fanoh yeah.

I will not say that the Dremel can not do the same thing. It can not, but can come pretty damn close to perfection. (it looks perfect but is off by X number of microns..I guess that only I care about that!) Obviously you need a jigsaw, and a steady hand to cut out windowswhich I do not want right now.

I should mention that any hole you cut out of your plastic bezel / front cover of your case, you need the following special instructions. This really only applies to fan holes / air ducts. I want to mount a mean 12cm fan on the front of my case. The front part of the chassis is where the fan will be mounted, and a similar hole needs to be cut out of the case cover / bezel / whatever. HOW?

Again I used a drill PRESS. I made a pilot hole (after measuring and laying it out) going through both the chassis and the cover. Viola! Now you can center the drill bit over each piece and cut out the circles individuallyI hope!

Again this pic given to us by the guys at Virtual Hideout.

File down (or use the Dremel but be careful!!!!!), to not only remove the burrs from the hole edges, but also make it as smooth as Britney Spears bottom. Done? Good.

The next step is the painting process, this part of the article, as well as the rest will be put on hiatus until I finish it myself :P and snap up some of my own pics!