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[Scratchbuild] HyperMod - Finished


Ch2pa

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Big update for the HyperMod:

The very good news of the week is that I got sponsored by Kingston for this project.

Kingston put at my disposal a SSD HyperX 3k 240GB!!

I would like to thanks them for their support and confidence in my project.

Here si the SSD:

cimg4040.jpg

Unpacking it:

cimg4043t.jpg

cimg4046c.jpg

cimg4048s.jpg

I will try to test this SSD soon ;)

Let's see what I did this saturday:

I drilled the bottom and the flanks to add pegs:

cimg4073t.jpg

In order to add some strenght to the structure, I added a crossbeam at the back, also fixed with pegs:

cimg4075.jpg

Here is the final position for the pegs:

cimg4077.jpg

And the definitive structure:

cimg4081.jpg

cimg4083w.jpg

I had a last operation to make to the bottom:

cimg4084.jpg

I made a pocket to give some room to the GPU:

cimg4086a.jpg

cimg4087.jpg

The wood structure is now almost finished, I just have to glue it and paint/varnish it!

Two weeks ago I made some OCCT stress tests on the CPU to check its temperature.

In a room at 18.5°C, with the stock 120mm at 700rpm, the die package did not exceed 48°C.

With no fan at all (fully passive), motherboard layed horizontally:

2012101301h39temperatur.png

The test failed due to too high temperature (package exceed 75°C).

With no fan at all (fully passive), motherboard layed vertically:

2012101301h09temperatur.png

The test passed though the CPU was very hot (cores were between 66°C and 71°C). But it is feasible to cool a Core I5 3450S with fully passive Hyper 612S!

Unfortunnately I need my heatsink horizontal :/.

I spent a lot of time thinking how to cool the CPU with a non visible fan, because I wanted the heatsink to look fanless. As it is the masterpiece of the mod, it has a huge importance!

I thougt about milling the Heatsink to integrate a 92mm fan but there was not enough space. Then I thought about using a slim 100mm, but it was to hard to integrate (I did not find a proper way to mill a 100mm deep pocket in the heatsink).

Finally, I made a third test with a 50mm fan layed on the top of the heatsink (after I removed the two upper fins). The fan produces about 5CFM airflow.

2012100602h57temperatur.png

And it is enough to cool the CPU! But 50mm is still too big, so I will go with a 40mm fan.

In order to integrate the fan, I first had to drill a vertical hole in the heatsink:

dsc0012cp.jpg

I used a drill press and a step drill bit for this task.

Here is the result:

dsc0015sxm.jpg

It is pretty clean:

cimg4050u.jpg

Second step was to make a 40x40x10mm pocket at the top of the heatsink for the fan.

I am gonna use this ADDA fan.

I started to cut the heatsink fin by fin:

cimg4051c.jpg

Then again it was a real brain teaser to find the better way to proceed. I tought about building a punch, using a hacksaw, using my Dremel as a milling machine...

But the easier solution is the simplest. I used a cutter!

cimg4052w.jpg

I made a scratch on the fin with the cutter and it was then possible to tear it cleanly (fins are only 0.3mm thick).

cimg4053.jpg

And most of all, it was quick! Here is the final result:

cimg4061.jpg

The cuts are not all very clean but they are invisible from the sides:

cimg4059v.jpg

I just miss the fan (it's in a plane between Honk-Kong and France right now) and I will be able to finish the heatsink.

Last thing I did this week-end: I finally experiment the final design of the mod, with the heatsink in position:

cimg4064.jpg

cimg4067g.jpg

cimg4063.jpg

I definitively love it! and you?

That's all for the week ;)

@brianwhite: yep, the mod is in good way to be finished in time :D!

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Short résumé of the work I did this week:

I started the cabling:

cimg4109.jpg

1st step: remove the inscriptions from the cables:

cimg4108k.jpg

Rubbing them with acetone is the quickest way to do it :)

Then stripping, setting of connector and filing in housing. One done, four to go:

cimg4110g.jpg

Five done:

cimg4112i.jpg

And the first Sata cable is ready:

cimg4113k.jpg

Test fit: (the cable is below the motherboard tray, it powers the SSD)

cimg4115j.jpg

This week I received the last piece of the puzzle:

cimg4120.jpg

So here is the complete rig:

cimg4122.jpg

I was also able to test the PCIe riser with the GPU. On first boot it didn't worked:waah:

Past the POST, the screen shut down at Windows Seven start.

I had to insulate the riser with aluminium to get it work:

cimg4125.jpg

I now need to find a proper way to make this insulation.

:)

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Here is the summary of what I did this week end:

First thing that I did was to finish the GPU holder:

cimg4128r.jpg

I add some aesthetic cut and a crimped nut. The nut and sandpapering were added after the photo was taken, sorry :D

Then I stuck the wood structure. First, the front panel wood cover:

cimg4129i.jpg

And secondly the whole structure:

cimg4130q.jpg

cimg4131.jpg

After the gluing process and some sandpapering, here is the result for the bottom:

cimg4135x.jpg

And the front panel: (that took me so many hours)

cimg4140.jpg

Another point that I finished is the CPU heatsink.

I integrated the 40mm fan directly on the second-to-last fin:

cimg4147x.jpg

cimg4151z.jpg

To make the fan breath, I cut the CollerMaster logo of the fin. The fan is fixed with 4 M3 screws and home-made silentblocs.

With the fan-fin assembled on the heatsink:

cimg4154.jpg

And with the last fin, the fan is invisible:

cimg4156.jpg

I just have to modify the fan cables (to integrate a resistance to undervolt it) and wire them through the heatsink.

Very soon some updates for the cables (under constructions)

:)

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Hello,

This week-end it was varnishing time:

cimg4157n.jpg

Here is the render of the first coat:

cimg4160f.jpg

It was not really dry when I took the picture that's why it shines.

Next week-end I will apply second coat.

Second activity of the week-end was to sandpaper and brush the aluminium sheet that I will use for the covers:

cimg4165.jpg

I used an orbital sander first, then hand-sandpapering with 120, 240 and 400 papers.

The goal was to eliminate this ugly scar:

cimg4169q.jpg

After some pass:

cimg4170i.jpg

I will show more of it when the covers will be ready ;)

Last thing that I did this week end was to properly insulate the PCIe riser.

I tried to use an antistatic bag for the insulation:

cimg4183i.jpg

It partially worked. I was able to boot and launch a Furmark stress test but the system went down at half of the benchmark.

So mixed the solutions, using both aluminium foil and antistatic bag with double side adhesive tape.

I started by placing the double side adhesive tape on the riser: (luckily it's exactly the perfect size! :))

cimg4184r.jpg

Then I glued the aluminium foil:

cimg4185yw.jpg

And finally the antistatic bag:

cimg4188f.jpg

The riser is ready for further benchmarks.

That's all for the week :)

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Hello,

as usual, here is the summary of the week-end's work.

I finally finished all the cables. Here is a how-to in four steps:

1-Stripping:

cimg4208.jpg

2-Crimping:

cimg4210.jpg

3-Plug-in:

cimg4212g.jpg

4-Result: two 6-pins custom GPU cables!

cimg4213l.jpg

This kind of cable is very quick to make: it took me only 30 minutes to do these two.

Family portrait of all the cables:

cimg4217g.jpg

From left to right: 24pins mobo, 4pins CPU, 6pins GPU, Mini-Sata for DVD, Sata for HDD and Sata for SSD.

I also modded the motherboard slightly by removing the stickers and adding mine:

Before and after:

cimg4200b.jpgcimg4206f.jpg

With the heatsink and SSD mounted:

cimg4220c.jpg

cimg4221ir.jpg

See you soon for updates :)

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