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 Post subject: Re: Cosmos Cruizer - Wiring
PostPosted: Fri May 09, 2014 8:29 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Another clean-up item checked off my list: Boxing in the top and front side bezels to hide all the ugly webbing and fiberglass remnants.

I got a sheet of 1/16" ABS and cut out the main pieces after making rough templates.
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Then I cut a bunch of pieces for ribbing and support.
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After fitting a base piece, I started gluing in the ribs and support pieces with ABS cement.
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Now the main piece has something to glue to.
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A shot of the left side bezel front. You can see why it has to be covered!
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With the front cover in place. The first of many test fits.
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Mating the front piece with the top piece.
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The right side bezel is in much better shape than the other one, but still needs to be boxed.
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I simply mirrored the original pieces to make these.
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After many refits, especially on the front due to the proximity of the front grill and faceplate, I finally got everything glued up. Here's the whole top with both side panels on the case. I scuffed the boxed pieces up in preparation for paint.
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My OCD is thanking me!


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 Post subject: Re: Cosmos Cruizer - Cleaning up
PostPosted: Mon Jun 16, 2014 2:01 pm 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Been finishing up a lot of minor details over the last couple weeks, trying to get all the panels' imperfections filled and smooth. Also had to make final adjustments to other parts that I wouldn't be able to do without the panels. Finally got everything boxed up and shipped to BSMODS for paint yesterday. :D
I hope it survives the trip, it's not like Bob and Rod don't have enough work to do already without having to perform reconstructive surgery as well.

So with all the panels out for paint, I must now concentrate on getting all the metal pieces ready to be sent out to the platers. Here are all the parts to be chromed..
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 Post subject: Re: Cosmos Cruizer - Cleaning up
PostPosted: Mon Jun 16, 2014 2:02 pm 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Sorry about the lack of posts, but due to the ridiculous amount of work still left to do on this case (and my site going down), I've been kinda preoccupied. So tossing a few pics up here and there is about all I can manage right now.

Anyway, while I got parts out for paint and polish, I've been taking care of lots of little things, like this distributor cap mod. This is a piece that will serve as a cover for the 24pin ATX connector. The four "spark plug wires" will plug into this piece, with the actual connector on the other side.

So I started with the terminals from an actual distributor cap, which I recently removed off my V-6 Xterra.
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I harvested four of the terminals from the donor cap.
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Lining them up how I'll be gluing them together...
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Drilling them out so the wires will pass through
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Fast forward past all the gluing, bondo, sanding, and smoothing, and we have this..
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And as a final parting shot, all the bracketry and support pieces that have been sanded and primed.
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That's all I got for now, but I will be getting some polished parts back tonight, so I'll be sure to post a shot of them. And then hopefully Bob will give me a painting update soon.


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Wed Jun 18, 2014 9:25 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Got parts back from the polisher yesterday. Here are a couple teaser shots...

Stainless pipe, before and after polishing..
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I assembled the grill first thing.
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I had the guy only polish the stainless pipes, grill pieces, top handle bars, and headers. I'll be taking care of the small stuff next week.


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Thu Jun 19, 2014 8:49 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Here's a quick update on the ATX 24pin plug cover...
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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Mon Jun 23, 2014 9:02 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
OMG

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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Tue Jun 24, 2014 4:48 am 
Team Member
Team Member

Joined: Wed Aug 12, 2009 12:09 pm
Posts: 565
Did it crack? Did you bake it or something?


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Tue Jun 24, 2014 6:14 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
phillyj wrote:
Did it crack? Did you bake it or something?


lol no, its fine. Just showing the amazing paint color. We're using a tri-coat automotive paint system that consists of a base coat, mid coat, and clear top coat. That piece is the bottom of my EK res.


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Tue Jun 24, 2014 9:33 am 
Team Member
Team Member

Joined: Wed Aug 12, 2009 12:09 pm
Posts: 565
Very nice. It's sure to win some awards.


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Wed Jun 25, 2014 12:00 pm 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
More teaser shots from BS Mods...

PPG Orange Vibrance base coat...
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Mid coat...
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Keyboard frame...
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A test piece showing the paint with clear coat...
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With just a couple weeks left until the lan, methinks I'm going to have a few sleepless nights ahead of me...


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Mon Jun 30, 2014 2:40 pm 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Another mini update and final paint teaser..

Slight modification on the EK tube reservoir brackets. I didn't like how they looked, so I filled in all the cavities with epoxy putty to make them look more solid.

Before..
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Filled..
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Sanded and primed..
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On the polishing front, I pretty much got all the small parts done over the weekend. All the tubes were really easy, but the 1/4" aluminum bars were pretty rough especially around the bends. I had to start with 80 grit on the orbital sander to get the sides flat again. Then I moved up to 120, then 220. After that, I switched to hand sanding with 400grit, then to a fine 3M Scotch-brite pad, and finally on to the polishing wheel using coarse and fine compounds. Here's a before and after shot..
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And finally I leave you with the paint teaser...
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This might be the last transmission until the LAN, because as soon as Bob delivers the case, I'll have zero time to be posting anything other than a quick FB pic.


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Tue Jul 01, 2014 4:52 am 
Team Member
Team Member

Joined: Wed Aug 12, 2009 12:09 pm
Posts: 565
Sweet. Good work and good luck at the LANfest. Are you going to the July 11 one? That's a tight window to finish.


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Tue Jul 01, 2014 6:05 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
phillyj wrote:
Sweet. Good work and good luck at the LANfest. Are you going to the July 11 one? That's a tight window to finish.


Yep, PDXLAN in Portland. And yes, I'm going to have sone sleepless nights ahead of me! But I think its still possible. Thanks for the good wishes. :)


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Wed Jul 02, 2014 10:11 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Ok, another quick paint update...

Bob has been taunting me for the past week with painting shenanigans, so I figured I might as well share..
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I was going to save these shots until after the case was done, but I just can't keep the fricken awesomeness under wraps! Bob really outdid himself on my flame grills..
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I literally cannot sit still I'm so excited to see all this in person. Should be arriving tonight!


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 Post subject: Re: Cosmos Cruizer - Parts out for Paint, Polish
PostPosted: Mon Jul 07, 2014 10:29 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Ok, so while I'm at work and not finishing my case, I figured I'd post some assembly pics..

Bob came down and stayed all day Thursday to help me out, and got a crap-ton of stuff done while I was stuck at work. I can't thank him enough! :D

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Got the upholstery done on the interior panels while Bob slaved over the main panel covering..
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The wiring on this thing is taking forever. Feeding the wires through the alu pipes is a royal PITA! But the end result will be worth it..
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The back side of the SSD module, wiring up the drives and lighting..
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ATX cable pinned with connector..
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Motherboard 12v power cables pinned and numbered. Will run continuity checks on all wires to match them up on the other end.
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Other side of the panel, waiting for PSU.
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Covering the PSU cover..
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Got all the blocks on the board, after detailing them in white/orange.
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Manifold in place..
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Rigid tubing in place..
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Polished mesh scoop insert..
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Tonight will consist of more wiring. Hope to finish up the PSU so I can move on to installing the rest of the stainless tubing and fill.


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 Post subject: Re: Cosmos Cruizer - Assembly!
PostPosted: Tue Jul 08, 2014 5:00 am 
Team Member
Team Member

Joined: Wed Aug 12, 2009 12:09 pm
Posts: 565
Very nice. You put much work into the rear panel also. I confused the front with the back.


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 Post subject: Re: Cosmos Cruizer - Assembly!
PostPosted: Tue Jul 08, 2014 8:31 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
phillyj wrote:
Very nice. You put much work into the rear panel also. I confused the front with the back.


Thanks phillyj. Yeah, that back panel was the bane of my existence for a while there.

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After struggling for 3 hours, I finally got the main side panel mounted to the frame. Had to modify a few things, and remove some paint layers in order for it to fit again. But with the help of my wife and a few clamps, I got it on..... and then I put the panel on the frame. :P

Now I can continue installing components and routing wires.
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 Post subject: Re: Cosmos Cruizer - Assembly!
PostPosted: Wed Jul 16, 2014 11:00 am 
Little Foot
Little Foot

Joined: Thu Jun 29, 2006 1:21 pm
Posts: 178
Location: Northern Cal
Well, I wasn't able to get the Cruizer case running in time due to leaky fittings. But I still wanted to show it, so I temporarily rigged it up with lights and fans..

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Now that I have some time, I will address the issues that arose as I was assembling it...
Electrical
- re-route wiring under floor so rear fans don't arbitrarily change modes
- Fix grounding issue with front LCD screen
- Add lighting to motherboard area
Cooling
- Fix leaks & refill
- Mix up correct color fluid
Cabling
- Clean up rear IO panel
- Reroute USB/DVI cables and cover
General
- Address panel alignment and fitment
- Finish and assemble hinged fuel door
- Finish and assemble Razer keyboard
- Add door popper feature with touch sensitive button

Should only be a couple more weeks and I'll have all the gremlins worked out and I can call it done. :)


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