Maximum PC

Hey gang, I've started the build for Cooler Master's media suite at 2010 CES. The D-9 concept was mine after seeing the movie.

I should know by first week of November what hardware CM will be sending me.




Conceptual drawing by E.E.L. Ambiense

The canvas for this PC build is the Cooler Master 840 ATCS



Adding window to Cooler master 840 ATCS


Using tape roll to make curved corner


Make first initial cut with your Dremel and cutting wheel, to allow use of Jigsaw and cut the window more efficiently



You have created slot, this allows using a Jigsaw w/ 18 TPI cutting blade





Using a Jigsaw is much quicker than using a Dremel to cut your window


Use a rounded side file to debur the jagged edges of the new window





Notice the window location doesn't reveal the drive bays, this was intentional.

looks very nice. Thanks for providing a worklog too, I don't think the mods will have a problem with this one.
dremel+jigsaw=surprisingly easy window cutting. Nothing else works nearly as well.

How much does a jigsaw+dremel cost? I want to get into modding, but i hate borrowing my neighbor's tools.

Dremel @ 69.99 @ Home depot
Jigsaw @ $40 @ Home depot

Upgrading the 840's stock 120mm exhaust fan to 140mm fan.

Cooler Master 840 ATCS rear 120mm exhaust


I'm holding up a 140mm Cooler Master fan over the stock 120mm grill. "Will it fit without anything obstructing it?"


The location of the 140mm fan resides along the crease on the back plate.


Making the initial cut with Rotary tool and reinforced cutting wheel before using Jigsaw


Using Jigsaw with 18 TPI metal cutting blade


Using rounded side hand file to clean up burrs along the edge of the cut.


140mm opening is cleaned up, next is drilling mounting holes for 140mm fan


vibration dampening fan grommets


Using a 1/4" size drill bit to make the mounting holes, this allows the fan grommets to fit.



Vibration dampening fan grommets installed.

wow, so you just took a straight shot with that jigsaw to cut a round hole? That takes skilz beyond mine. As for the dremel, I'm still rolling with an original- they were more then $70 back then.

Nice to see you made to to Maxpc i have been following this on XS for some time now.

Cool! Thanks for the comments!

I like the improved "how to" photos. This is good! Exactly what we like to see! Looking forward to seeing the results!

If you are serious about modding, I recommend this kit:
http://tinyurl.com/Dremel-MultiPro-77-Acces-kit

Thats cool! Thank you for the feedback and suggestions. I really like the F-150 pick-up from District 9


For the exhaust fan grill, I cannibalized an early Monsta Rad grill prototype we made this year.

We've cnc milled the "District 9" design in the Cooler Master 840 aluminum intake plate. The recessed center portion will be the CM case badge

Lookin' sweet so far!

How much is that mill machime, and give it to me!

CNC's are damn expensive, but you can order anything to be CNC'ed from a local machine shop. I know for sure that the vast majority of them will take an autoCAD file and dimensions (and money of course) and send you back the finished product.

We lease our HAAS 5 axis, you can pick up a used one for $120,000

I've cut the window from Lexan. It's tougher than plexiglass/acrylic, but 2 or 3 times more expensive. It won't shatter or crack "easily" You can buy Lexan sheets at Home Depot, Lowes and some hardware stores like Ace.

The window will be fastened with 1/4" socket head screws, for reinforced armour look

Using center punch to mark each fastener hole.



Roper Whitney No. 5 Jr Hand Punch kit available here
Hand punch (estimate $60 new)





"Look Ma, No deburring needed!"


The benefit of using Lexan is that you can drill or hand punch it without cracking it.



Clean hole cut! I love Lexan.





Ironically our concept drawing calls for bullet holes in the Lexan "bullet proof" window...lol

Cooler Master's hardware list for their CES show display

1 x Intel Core 2 Duo E8500 Wolfdale 3.16GHz 6MB L2 Cache LGA 775 65W Dual-Core Processor
1 x Intel Extreme Series DX48BT2 X48 Motherboard
1 x Silent Pro RS-600-AMBA-D3
1 x CM MITX Cooler 38mm tall (will be replaced with future V series cooler)
1 x Sapphire ATI Radeon 4870 512MB
1 x 4GB DDR3 Kingston 1600mhz memory kit
1 x WD 500GB HDD
1 x DVD drive

Silent Pro RS-600 Watt-AMBA-D3 PSU
http://www.newegg.com/Product/Product.a ... 6817171036







Are you a fan of the Black Ribbon power cables?

wow that's kind of a craptastic hardware list for such a nice case.
the mod looks great though. As for your question, nylon-mesh sleeved cables are so much better.

The concept called for bullet holes in the window



Using 3/8" drill bit




Using wire cutter to make cracks around the hole


Etching Rotary Tool (or Dremel) Engraving Bits


Using the dremel to emulate some cracks

you should have just taken the side panel to a shooting range.

I thought he said they were using Lexan, which is bullet proof...

no, lexan is not bullet proof. lulz. I've used it before- it's sturdier then plexiglass, but certainly NOT bullet proof. He said that the theming was to make it look like a bullet proof window.