[Scratch Build] Combine Turret

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Hi everyone.

I am an entry-level modder from Ukraine and this is my second modding project.

I have no sponsors, so project budget is limited and hardware is not state-of-the-art.

CONCEPT

If you ever play Half Life 2, you have to remember Alliance turrets.

This project will be a console type PC, with optional table mounting. Not an exact copy, but very close to the original ceiling turret. And maybe it will looks like a HL3 turret, who knows?

So let’s start making a Combine Turret.

Here is the hardware list:

CPU cooler: Cooler Master Gemini II M4

MB: Gigabyte H55N-USB3

CPU: Intel i3-550

MEM: Hynix DDR3 2x2G 1333MHz CL9

PSU: Flex-ATX Seasonic SS-250SU

GPU: Asus HD5770 512Mb GDDR5

HDD: SATA 160Gb Samsung SpinPoint F1 8Mb

DVD: DVD-RW SATA Sony Nec Optiarc AD-7690H (slim slot-in)

CASE: full custom (picture is not available now)

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The main inspiration object is Combine Ceiling Turret:

So I’ve plane to make the case not in the style of the game but highest possible close to original source.

Also inspiration objects - Alliance turrets:

Layout

2D layout:

Comments are unnecessary - all self-explanatory

3D layout:

The frame going to make from aluminum angle bars, side panels - glass-fiber plastic, and the rest during the process.

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To initiate the process make a power supply unit angular mounts:

Adjust the attachment holes and fan cut-out:

Time to handle a framework. The problem is that the case almost have no right angles, all surfaces are sloped - will have some fun

The pair of rear frame’s profiles:

Manual bending:

Angle revision:

Forming the rear side of the frame:

HDD mountings:

Mid frame profiles cutting:

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Trying on the motherboard with box CPU cooler (CM Gemini II M4 is not yet redy)

Rear panel cutouts:

Have to make cutouts for memory modules too:

Frame assembly.

The frame is almost ready, can place the hardware.

Installing PSU:

PSU cable assembly:

Here is the secret ingredient - furniture hinge.

“What for?†you can ask.

The fact that the lid will be a separate structure that is rotated forward relative to the frame.

Lid close position:

Lid open position:

So, a furniture hinge serves as a pivot joint.

A video card housing will slide back through the guide:

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Graphics card and cooling system added for the sake of completeness:

Now the PSU, MB & HDD fixed

Dimensions check

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Its time to modify the low-profile Cooler Master Gemini II M4 CPU

Despite the fact that is the lowest Cooler Master cooler, I have to make it even thinner.

First, remove the fan, and tilt radiator:

In rotate position heat pipes run into the capacitors and the cooler base not in contact to processor

Need to raise the cooler on the heat sink:

Tinkering heat sink and heat pipes, a second attempt

To warm up the heat pipes cooler is placed in a container with boiling water on the gas stove

Heat sink roasting

Cooler assembled

Modified CM Gemini II M4 tests on OCCT v.3.1.0:

With stock fan - better then original!

Passive –fail (even without load):

With Titan TTC SC-04 blower

That’s my choice:

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It’s time to make a frame holder.

The joint plate at first:

Made from 1,5mm thickness steel:

It attached to rear part of frame:

Lets take a closer look at the mounting cantilever:

It’s made from steel perforated plates and aluminum angles:

Trapezium-shape part cut-off from box-shaped level tube

by the actual size printed template (do you think it’s too big for mini-ITX case?) :

Vee-type part in closer view:

The video output extension cords and power cord will be tracked inside.

Something like this:

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It is time to prepare a little bit of aluminum sawdust.

Start to make a MB rear panel cover.

The top canopy at first:

Then side parts:

Testing:

Side parts will be removable, attached with screws.

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As I wrote early, video card housing will slide back through the guide.

Telescoping rail guide (from furniture set) need to be shortened at first:

Both original and shortened guide:

Close position:

Open position:

Fixing at mounting angles:

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Swivel lid will make from fiber-glass plastic.

Marking:

Ventilation holes contours marked trough laser printer paper copy and electric iron:

However forgot to mirror the image (smile)

Predrill:

A hacksaw and needle files working result: