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Nicholas Falzone

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Everything posted by Nicholas Falzone

  1. My peripheral mod will be of the Cooler Master MK850 Keyboard along side the Control Pad. I mostly wanted to make these pieces fit in with the aesthetic of the case better as they are already beautiful stock. The plan was to cut some Wenge and put that in place of the stock foam pads. To do this, I used my bandsaw to cut the Wenge at an angle and chamfered the edges. I then sanded everything to 600 grit for the smoothest possible finish. Before finishing, I added some magnets to attach the Wenge to the Keyboard and Control Pad since I no
  2. I wanted to finish up the Kumiko on the PSU side. I did this the same way as the fan grille. Only the outside frame has glue, the rest is simply friction fitted in place. Angle guide blocks: Getting pieces cut and fit: Main pieces all done: Now for a small Spruce panel to cover the wires: It was late so I mostly used hand tools: Fitted: A few shots of the progress so far. The loop is filled but has quite a few bubbles so I'm working on getting those out:
  3. I'm curious about this as well. It will be down to the wire for me.
  4. Its been a long time coming but its finally time to assemble the loop for the final time. Starting with making the final O-rings for the distro plate: Cut with a razer and glued together: Before attaching the pump, I decided to make some Wenge spacers since the bolts were a little too long: Then I attached the inside fan grill to the radiator: The clearance was super close on the fittings to the radiator: Installed: Installed fo
  5. I wanted to make something to hide the PSU a bit and tie this section of the case in with the rest. I decided on some more Kumiko reminiscent of the design on the fan grill. It will go here: I played with some scraps to get a design I liked. This will also cover the wires entering the PSU: I got to cutting, making the pieces slightly thinner than the fan grille pieces so they would fit: Testing fitment: Gluing it
  6. Routing wires through the front plat and trying to keep them flat is fun: Wiring through the acrylic panel is fun too: I needed to do both wires on the pump so that was next. I was nervous abut screwing this up but it turned out ok: Sleeved: More wiring: All buttoned up! Now I started routing the GPU power cable. There is actually an LED strip right under this too: Clean floor connection: Lastly I wanted
  7. Lots of pins: I made some double cable combs to keep things tidy: Trying to get the length right: A while later everything looks good. Fingers crossed that I put things in the right holes: Next I routed the CPU power cable and made some more cable combs for it: I then put more pins and attached it to the power supply. Next is time to work on the front panel wiring caddy thing. First thing is to
  8. I hate wiring so I wanted to make as easy as possible in this case and try to think ahead. I made many models of the wiring and mocked it up as much as I could before embarking on the real thing. The cables that came with the Cooler Master SFX PSU were also really nice so this made it easier although I made most of the cables myself. One of the big cables is the 24pin which turned out to be exactly the right length: This design eventually would change but it started like this. I also wanted to make custom cable combs out of wenge. This also went t
  9. I wanted to simplify the look of the motherboard a bit to match the clean design of the case. For this I used a combination of Wenge and brushed black aluminum. First up is the ram: I then drew up the motherboard pieces in cad and cut out samples to make sure my measurements were correct: Then I cut out the real thing is 2mm aluminum. Then I sanded the e
  10. Watercooling: I chose 12mm clear PETG for this case, using some bends also. I have not done bending before so this was a new challenge and I have more respect for people who do this often, its not easy. I first laid out all the fittings to see where they'd need to go. And got my tools ready: I used a cheap Barrow tubing cutter and a Primochill tube trimmer to get all the tubes dialed. Luckily I bought lots of extra tubing since there were a few misshaps, especially on the double b
  11. I wanted a bit of Pizazzzz in the center acrylic panel so I decided to route a groove and add an Alphacool LED strip in there. Luckily these are super thin so the groove could be small. I used the router table with a spiral carbide bit:
  12. I went back and forth on whether to make a shroud for the radiator and fan setup and decided to do it since it would clean up the inside of the case a bit. I made a model to make sure it would work with the other components. It would be made out of a combination of Wenge and brushed black aluminum from A.C.Ryan. I resawed some Wenge on the bandsaw and ran it through the drum sander to make it smooth: I then cut the pieces to length: For the joinery I wanted something simple but strong so I de
  13. I decided to add some black A.C. Ryan mesh on the outside where the Kumiko covers the fans, for the extra contrast. This might hurt performance a little, but it looks slick so its an acceptable trade-off. At first I tried to machine it on my CNC but since it is steel, and a bit wavy at that, it went about as well as I expected. Instead I decided to use some tin snips and this worked great: Once cut to size, I used a template I made for the radiator shroud to mark and drill the holes to allow
  14. My CNC machine made a decent but not perfect finish on the acrylic edges. To clean this up I just used sandpaper. I do not want a polished edge as I like how the polish/satin look together so I'm just aiming to get an even matte surface. I put some sheets of 220, 320, and 600 grit sand paper on my table saw, since it is a flat surface, and went to town. How it started: After 320grit: After 600grit I used a Wenge sanding block for some of the smaller pieces:
  15. With everything sanded I could start the finishing process. I used Danish Oil then a top coat over that with everything being a wipe-on then wipe-off kind of finish. Making progress!
  16. A monumental moment came when I could finally glue up the big wood pieces. I started by sanding the insides of the pieces to be glued. I mixed some wood glue and dye together to make a dark glue just in case the joints weren't perfect. I did the same for the PSU caddy: Then it was time to start gluing: Once the glue was dry I sanded the joints smooth
  17. With my stock cut to thickness and the model adjusted I started cutting out the real thing. I used a double flute 1/4 inch bit: From here I started on the cover piece. I used a 2mm Single Flute bit and a 1/4 inch bit for this: I forgot about the pump wire cover so at the last minute I added it into the model and cut it out of the same piece: And both together: To attach the two halves I made threads in the Wenge. I
  18. Next up was a wiring harness and cover that will go next to the pump distro and keep the wiring tidy. First I needed to figure out how big it would be and then I started modeling it in cad: When I had a design that seemed to make sense I cut out a practice version: Then I started milling some more Wenge to make it out of. To start with, I used my bandsaw to resaw a piece of Wenge. This will make the top and bottom of this assembly and the grain should match perfectly: I ran these through the d
  19. Its a bit nerve wracking making more holes into something I have so much time invested but I figured it would be easier and safer than hand drilling: Luckily no surprises. I did not have any black button head screws so I made some:
  20. One reason I moved the wiring access to the GPU side is so I could put a cover on it without hitting any motherboard parts with screw heads and shorting out the hardware. Luckily I still had some 1mm brushed black aluminum from A.C.Ryan to make a cover out of. First I made a practice version: Once I was happy with the size and hole placement I started cutting the real version. I used a 2mm Single flute bit with a bit of alcohol to make it cut more cleanly. Ideally I'd have a mist system for this:
  21. I wanted an elegant way to hold the PSU power cable to the acrylic and decided on some little Wenge brackets. This took a few tries to get something that I liked: Final version: I chamfered the edges to match the rest of the case: I wanted the same countersunk holes and this required some creative work holding: But it worked: Once they were all cut I drilled and tapped corresponding holes in the acrylic:
  22. Earlier I routed a hole and groove for the PSU power cable and fan cables shown below. I wanted to put a cover on this to hide most of the wiring: I picked a piece with matching grain to make this as hidden as possible and ripped it to the right size: I thought about using the CNC for this but hand tools worked better in this case: Getting close, I just need to do the rounded corners: And a small slot for the cable to pass through: All done and
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