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 Post subject: Cooler Master 840 Project
PostPosted: Wed Oct 28, 2009 4:00 am 
Sharptooth
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Location: Mpls, Mn
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.

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Conceptual drawing by E.E.L. Ambiense

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

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Adding window to Cooler master 840 ATCS
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Using tape roll to make curved corner
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Make first initial cut with your Dremel and cutting wheel, to allow use of Jigsaw and cut the window more efficiently

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You have created slot, this allows using a Jigsaw w/ 18 TPI cutting blade
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Using a Jigsaw is much quicker than using a Dremel to cut your window
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Use a rounded side file to debur the jagged edges of the new window
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Notice the window location doesn't reveal the drive bays, this was intentional.

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 Post subject:
PostPosted: Wed Oct 28, 2009 10:20 am 
Million Club [PC]
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looks very nice. Thanks for providing a worklog too, I don't think the mods will have a problem with this one. :wink:
dremel+jigsaw=surprisingly easy window cutting. Nothing else works nearly as well.


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 Post subject:
PostPosted: Wed Oct 28, 2009 10:56 am 
Sharptooth
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How much does a jigsaw+dremel cost? I want to get into modding, but i hate borrowing my neighbor's tools.


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 Post subject:
PostPosted: Wed Oct 28, 2009 8:31 pm 
Sharptooth
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Location: Mpls, Mn
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
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I'm holding up a 140mm Cooler Master fan over the stock 120mm grill. "Will it fit without anything obstructing it?"
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The location of the 140mm fan resides along the crease on the back plate.
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Making the initial cut with Rotary tool and reinforced cutting wheel before using Jigsaw
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Using Jigsaw with 18 TPI metal cutting blade
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Using rounded side hand file to clean up burrs along the edge of the cut.
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140mm opening is cleaned up, next is drilling mounting holes for 140mm fan
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vibration dampening fan grommets
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Using a 1/4" size drill bit to make the mounting holes, this allows the fan grommets to fit.

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Vibration dampening fan grommets installed.
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 Post subject:
PostPosted: Wed Oct 28, 2009 8:50 pm 
Million Club [PC]
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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. :wink:


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 Post subject:
PostPosted: Thu Oct 29, 2009 12:07 am 
Thoroughbred
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Nice to see you made to to Maxpc i have been following this on XS for some time now.


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 Post subject:
PostPosted: Thu Oct 29, 2009 2:59 am 
Sharptooth
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Cool! Thanks for the comments!


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 Post subject:
PostPosted: Thu Oct 29, 2009 4:01 am 
SON OF A GUN
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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


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 Post subject:
PostPosted: Thu Oct 29, 2009 9:40 am 
Sharptooth
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Location: Mpls, Mn
Thats cool! Thank you for the feedback and suggestions. I really like the F-150 pick-up from District 9
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For the exhaust fan grill, I cannibalized an early Monsta Rad grill prototype we made this year.
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 Post subject:
PostPosted: Fri Oct 30, 2009 6:06 am 
Sharptooth
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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

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 Post subject:
PostPosted: Fri Oct 30, 2009 6:49 am 
Klamath
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Location: Roe Dilund
Lookin' sweet so far!


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 Post subject:
PostPosted: Sat Oct 31, 2009 6:14 am 
Team Creamsicles
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How much is that mill machime, and give it to me!

:lol: :lol: :lol:


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 Post subject:
PostPosted: Sat Oct 31, 2009 7:16 am 
Million Club [PC]
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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.


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 Post subject:
PostPosted: Thu Nov 05, 2009 9:27 am 
Sharptooth
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Location: Mpls, Mn
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.

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

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"Look Ma, No deburring needed!"
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The benefit of using Lexan is that you can drill or hand punch it without cracking it.

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Clean hole cut! I love Lexan.

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


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 Post subject:
PostPosted: Thu Nov 19, 2009 6:01 am 
Sharptooth
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Location: Mpls, Mn
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

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Are you a fan of the Black Ribbon power cables?

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 Post subject:
PostPosted: Thu Nov 19, 2009 6:05 am 
Million Club [PC]
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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.


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 Post subject:
PostPosted: Thu Nov 19, 2009 10:46 am 
Sharptooth
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Location: Mpls, Mn
The concept called for bullet holes in the window

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Using 3/8" drill bit
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Using wire cutter to make cracks around the hole
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Etching Rotary Tool (or Dremel) Engraving Bits
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Using the dremel to emulate some cracks
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 Post subject:
PostPosted: Thu Nov 19, 2009 11:44 am 
Million Club [PC]
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you should have just taken the side panel to a shooting range. :wink:


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 Post subject:
PostPosted: Thu Nov 19, 2009 12:04 pm 
Sharptooth
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I thought he said they were using Lexan, which is bullet proof...


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 Post subject:
PostPosted: Thu Nov 19, 2009 2:01 pm 
Million Club [PC]
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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.


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