Insolent Gnome Posted September 1, 2019 Author Share Posted September 1, 2019 With the shell made and sort of under control, it is time to work on the inside. I planned for everything to fit but I know how my plans usually turn out, so I did some test fitting.Stand ins for the 240mm radiators and fans.Getting them situated so they don't interfere with the tray.Speaking of trays, I need to figure out what I'm doing with mine. First thought, sheet of aluminum cut to shape. And the cardboard template.And then figuring how the hardware would sit on the tray.Before we continue on with the building, I should probably revisit how my plans never quite go...as planned. From the beginning I've been racking my brain on how to work out a monitor. It's a pain because even though there's plenty of room for even a widescreen 24" like I normally use, it would have to transport in a portrait orientation and then somehow rotate into a landscape orientation. So that adds complexity, weight, and thickness. And thickness is becoming a concern. This thing is not small so anything I can do to shave it down is a bonus for when I actually have it on. So I can ditch the widescreen and go with a small portable monitor. But then it's a tiny crappy monitor and you still have some extra thickness. Just make it so I can transport the monitor and assemble it separately on site. But I still have at least an inch of thickness plus then the whole back has to open so you can get it out.Plenty of options to get a monitor in the pack, just all of them make the pack even more unwieldy. So executive decision...leave the monitor out. This also makes figuring the straps out soooooo much easier.Is it less cool? Perhaps. But it's more "me" friendly and if I really need to take some sort of monitor in the pack, I'll look at a VR setup. I definitely have the horsepower for it.So with the executive decision made to go for a more wearer friendly design(thinner and lighter), I started thinking about that sheet of aluminum I was about to stick in the case. Did I really need 'all' that aluminum or could I cut a lattice out that would be strong enough to hold the parts and attach the straps to?And why am I thinking about this in terms of aluminum anyways? I can make a lighter and stiffer lattice out of carbon fiber and I happen to have everything to do it. Well, almost I had to order some expanding foam.This is a polyurethane foam that's used for floatation in watercraft. Think of it as the spray can of expanding foam on steroids...and meth...and maybe some PCP. These two bottles will give me 2 cubic feet of foam that I can use as my mold for my frame.Getting my shell ready to be molded. I didn't have enough foam for the whole thing and I didn't need a full mold anyways so I blocked off part of it. The garbage bag is a liner to make it easy to get back out of the shell.Mixed part A and part B and dumped it in. This stuff gets a little warm.Kinda looked like bread rising, so I guess now I have a loaf of foam in the shape of my shell.Next I cut it down to where I wanted my frame to be and filled some air pockets with some regular foam from a can.I laid out my component locations so I knew where my frame needed to run.Even had room to slot in a couple of 92mm fans in the bottom for more air flow.Laying out my lattice with tape. Some spots I wanted wider to carry more load while others were more for bracing and were thinner.Made a couple of sanding blocks to cut channels in the foam.Now some wax(which was useless) and 216 strips of carbon fiber.And then epoxy it up, layer by layer. 8 layers in all.After getting most of the foam pulled off, I wound up with, amazingly, what I was hoping for. I about did victory laps around the house.It still needs to be cleaned up and the shape refined. And I'm seriously considering adding a solid layer of CF front and back to pretty up the look. Other than that though, I'm super happy how this is going.Thanks for wading through this long update and thanks again to my sponsor: Link to comment Share on other sites More sharing options...
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