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Distro Plate Part I

 

This will take a while but here is the first part of the distribution/pump/wiring plate.  I decided to start on the smallest part in case I screwed it up and needed to start over.  For all these cuts, I used a single flute bit, either 1/4 inch, 1/8 inch or 2mm for all the small stuff.

 

Here goes nothing, this will hold the pump:

 

_1010448.thumb.jpg.3d32477cd1d4f90521ccd704a962371b.jpg

 

First cuts made:

 

_1010449.thumb.jpg.20e3b58a13ad0e9c84b1d98da3288d30.jpg

 

Threads proved challenging for me, partially because I forgot what I had figured out when I did them the first time.  Eventually I got them to work though:

 

_1010451.thumb.jpg.9b2807616ecfa93d9351d7c45a2f117f.jpg

 

_1010450.thumb.jpg.f4e89d65b579020e10bcf8b7f8f3216d.jpg

 

_1010452.thumb.jpg.0d9fa12b3cd9ccb024b6680f96aed2dc.jpg

 

After this I flipped the piece over and cut all of the screw holes as well as water channels:

 

_1010453.thumb.jpg.96524767be8d4f2e86a458fc3161f9be.jpg

 

 

 

Edited by Nicholas Falzone
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Meet ikigai (生き甲斐) (pronounced (ikiɡai) a Japanese concept meaning “a reason for being” The word refers to having a meaningful direction or purpose in life, constituting the sense of one’s life b

With the practice over it was time to commence to the real thing.  I chose this piece of wenge because I liked the way the grain flowed and wanted to feature this around the case. I cut each piece wit

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Distro Plate Part II

 

This is a little out of order but it will all make sense later.  I was going to put wiring access on the motherboard side but I eventually figured out it made more sense to put it on the GPU side.  I did many iterations of this design that I used for mockups but I'll cover that more in the wiring section.  However I decided to cut the wiring channels while also doing the water cooling part of the distro plate to minimize setups:

 

Blank Slate:

_1020456.thumb.jpg.110ad57ff6d4eddcce6c78bfd844d2fc.jpg

 

First blood. The beginnings of the wiring channels.  This will lead to the RGB header on the motherboard:

 

_1020457.thumb.jpg.eee4289077a0490d4d4ab6cc366a8367.jpg

 

More channels.  This will hold the CPU power cable along with RGB lighting hub:

 

_1020458.thumb.jpg.b9cdd72c641b01951b86dc381029d4d3.jpg

 

_1020459.thumb.jpg.9f2d06c01e0e8c5be713ac0939365958.jpg

 

_1020460.thumb.jpg.a8227e692673adc095dc2650203bcb9e.jpg

 

From here I started the water-cooling section again, first by drilling about a million holes:

 

_1020462.thumb.jpg.16abf26091962ed820ad4ed11d41dbef.jpg

 

_1020464.thumb.jpg.0110c85f8590513e94ed7cbf4f50a41b.jpg

 

After that, I flipped over the work piece and routed the channels for the water cooling along with the O-Ring channels:

 

_1030465.thumb.jpg.4543e0cad8424a5df21755568c8e8325.jpg

 

_1030467.thumb.jpg.f97a27de89e4fcc7739f39afe01e5163.jpg

 

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Practice vs the real thing:

 

_1030471.thumb.jpg.6a76bd6179abd1d2ed80e3dcd94802d0.jpg

 

With fingers crossed I combined the two sides with some practice o-rings to check fitment.  To my delight everything worked out:

 

_1030472.thumb.jpg.2d4931967e32b9354bbd5a05fc831e0f.jpg

 

_1030473.thumb.jpg.c4c3508954816a33ca6549816b8be038.jpg

 

More to come soon...

 

Edited by Nicholas Falzone
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Since I am making a pretty small PC I needed a pretty small power supply.  Luckily I got my hands on a Cooler Master 650w SFX power supply which is surprisingly small for how much power it has:

 

_C120348.thumb.jpg.15f7da92ed2e0879b3ec7da4dec15205.jpg

 

I wanted to make a holder for this that goes with the rest of the case and since Wenge is so strong, I decided to make a thinner holder with this.  As usual I made a few test pieces to get the basic dimensions:

 

_C200385.thumb.jpg.cfe2bbb738317e776760761f14cc2b25.jpg

 

I then needed to get the stock ready.  I resawed some Wenge stock with my bandsaw:

 

_C270403.thumb.jpg.c88b521880a9e321972940386d0da258.jpg

 

_C270404.thumb.jpg.b712810d7da4b2dac242fe0987f1ece6.jpg

 

Resawing left a surprisingly smooth surface but I cleaned it up with the drum sander anyway. First things first though, time to glue up!

 

_C270405.thumb.jpg.e96a3332844db8e994596e3ada7eacc2.jpg

 

All cleaned up:

 

_C270413.thumb.jpg.a1a807a705233a7c9a95f87b7e6f0f8a.jpg

 

Similar to the main case Wenge, I wanted the grain to be continuous so I cut it accordingly:

 

_C270415.thumb.jpg.df4217c117e7af0dd01226e095041062.jpg

 

_C270417.thumb.jpg.0bfed05746d36f057b48f40ea71782de.jpg

 

wanted to showcase dovetails as a design element in case so I chose to use them again here. Luckily these were much easier as they were much smaller.

 

Marking:

 

_C270419.thumb.jpg.1bf2771bd06759db75694660f035dc3c.jpg

 

First cuts:

 

_C270420.thumb.jpg.7b5bd9c76fe1b025aa753fb9e9006cdf.jpg

 

Marking some more:

 

_C270422.thumb.jpg.5e8c0bbff10fd6555f615e3ab936d763.jpg

 

_C270427.thumb.jpg.db0be2ea383f72cb975bafc9e2dfd23d.jpg

 

More cutting:

 

_C270428.thumb.jpg.617b239029d05a8646a6cfc63906b428.jpg

 

And after some cleanup we end up with more dovetail joints:

 

_C270429.thumb.jpg.17ea2829029f76c40ca5c962fa02b590.jpg

 

_C270432.thumb.jpg.f2ae4dd1342ec7a136e0264442076d3c.jpg

 

_C270433.thumb.jpg.016ac9ba7d7038428b5468393935a5d6.jpg

 

I needed to make the cutout to mount the PSU to so I cut this out on the CNC with a 2mm O flute bit:

 

_C310441.thumb.jpg.953c1d627b058d5954e7207e469e1e26.jpg

 

_C310443.thumb.jpg.b8e2053cfbc8b1eb2667ed0cee57495e.jpg

 

 

 

It works!

 

_C310444.thumb.jpg.0d2ddfebfd2727f31c5e238bc192d3eb.jpg

 

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_C310447.thumb.jpg.c6b7fc3dc4c5ecfdbde0c222dd26cfe1.jpg

Edited by Nicholas Falzone
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I decided to attach the PSU bracket to the acrylic with both screws and a dado joint.  To do the dado, I used my trusty router table:

 

_1070508.thumb.jpg.6edf05cc0cfb83a69c58d5b1ed50bfd0.jpg

 

_1070506.thumb.jpg.40ae0ab6a32d93560088af5a40292cd3.jpg

 

_1070511.thumb.jpg.5ec74b90a3864f012178d98431c2be7a.jpg

 

_1070509.thumb.jpg.bc388464720c70574f0cd915cdf942fb.jpg

 

With this done, I located some holes to screw the bracket into the acrylic and used the same 6-32 screws I've used on most other things so far.

 

_1070516.thumb.jpg.2de9bedb3aa1f8323a94eefa922b2a8f.jpg

 

_1070517.thumb.jpg.c32eaf5c0103a516a553fe920ac03f01.jpg

 

_1070521.thumb.jpg.b383bee1a0614b55fca8d4aa2210a90e.jpg

 

_1070519.thumb.jpg.ad4eb5da0161e7df89f622f24282e375.jpg

 

Next I needed some vent holes for the PSU fan and some holes for the power supply cables.  I decided on a simple design that would get the job without attracting too much attention to itself.

 

_1080524.thumb.jpg.cc69172bb1f8e92e8d40d808c2e8cfb5.jpg

 

_1080529.thumb.jpg.e0144e2cec3c801e5ff738b3959a405f.jpg

 

 

 

 

 

 

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Once I had the holes for the GPU and Motherboard made into the central acrylic panel and knew where they were going to sit in relation to the bottom wenge portion, I could make the holders for these along with corresponding holes in the Wenge.

 

They would look something like these:

 

_C130349.thumb.jpg.db0d7d8229a101dc1504420fadb4cea0.jpg

 

_1030480.thumb.jpg.c6eaca2be9510ec1bf3ebfb219ca8d20.jpg

 

I used more of the 12mm acrylic:

 

_1030481.thumb.jpg.f9882a2975e97ef7df95d1fa08ca3695.jpg

 

And cut them out:

 

_1030484.thumb.jpg.98735d607d52d15daa7de89cfc23b897.jpg

 

_1030483.thumb.jpg.8d12703abe0455d384c0bdd4ede7e039.jpg

 

From there, I marked their placement on the Wenge and matched up the holes on the real thing vs the CNC model:

 

_1030486.thumb.jpg.66560e87ae7d0874aa98cd29d0c088a0.jpg

 

_1030487.thumb.jpg.91408d1b504d16734bd5cae19d5bf221.jpg

 

_1030489.thumb.jpg.9aa862e40a34febdf8d7c078e0915367.jpg

 

Luckily I measured well and got the holes in the right place:

 

_1030490.thumb.jpg.2ed4f4abd6037f5b954e0638cfb5febc.jpg

 

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_1040501.thumb.jpg.735cb1faa3a1caf51282ddda9844a372.jpg

 

Next I made holes from the bottom to attach the acrylic with countersunk screws:

 

_1040502.thumb.jpg.0ec6236efc38c7a4293f55d3bc1663ab.jpg

 

_1040505.thumb.jpg.b0dc6f050854b3c756890660c20cb5f0.jpg

 

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Lastly, I sanded the edges and made a slight chamfer:

 

_1080527.thumb.jpg.024c7a1c5b74bca2a7ab1e7bf27e2800.jpg

 

_1080528.jpg

Edited by Nicholas Falzone
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I needed a little piece to hold down the GPU to the acrylic mount.

 

_1090541.thumb.jpg.4ee7ea48919d5d7f2e745f9bbda274e3.jpg

 

Eagle-eyed readers will notice how the photo above does not match the final version.  This is because I kept messing up and made this three times.  Slow down to speed up is my motto but sometimes I forget.  I also cut out the profile on the bottom as seen in the photo:

 

_1090542.thumb.jpg.ffa7414067540c47c122f0b9919081a5.jpg

 

_1090544.thumb.jpg.7b451ac0efb47cc83e5fb604e8fb22fa.jpg

 

And the final version:

 

_1090547.thumb.jpg.9814701b6b868915aa4924009d0ea812.jpg

 

_1090548.thumb.jpg.1966d4df231fef8dcd16d350531e8ea2.jpg

 

 

 

 

 

 

 

 

Edited by Nicholas Falzone
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To further hold the heavy GPU assembly up, I decided to attach a bracket at the top that slips between the PCB and the waterblock.  I made a quick test one to see if this would work well enough:

 

_C130350.thumb.jpg.5e455caf21d04a6569f4851bbafa284a.jpg

 

_C190374.thumb.jpg.8838e79005b8dc498d7e362c8f6fe9de.jpg

 

I had plenty of off cuts of Wenge to make small parts with and I liked the grain of this one:

 

_1090550.thumb.jpg.4f1ba94a1689bfd02b3e2066c0edf832.jpg

 

_1090551.thumb.jpg.44b91e78b1a28715becf02fba02ec03b.jpg

 

My plan was to CNC route the holes but use my router table for the rabbet:

 

_1090553.thumb.jpg.b260713495ce1dcc10507ac0338130a8.jpg

 

When I started to route the rabbet, the hardness of the wood combined with the small size of the piece made it seem sketchy so I instead CNC'd it as well:

 

_1090558.thumb.jpg.75a562de68ca82c306fd955824259356.jpg

 

_1090560.thumb.jpg.36cd5c0ab1ec341b6cdc7f3db1a31229.jpg

 

Next I needed to make a little cutout where a standoff was blocking the Wenge:

 

_1090561.thumb.jpg.da059dff17e5556b2a35bed6a387f129.jpg

 

_1100562.thumb.jpg.dc19d94354a006301f91acf04a94e082.jpg

 

Once I drilled/filed this out, it fit great:

 

_1100566.thumb.jpg.a023bff75459ca525e042af29e855ecc.jpg

 

From there I drilled and tapped holes in the acrylic:

 

_1100565.thumb.jpg.51fe80449469b846adf2525662597f5a.jpg

 

_1100564.thumb.jpg.6a3d5c9dc5eab0e32aa0423e672d4590.jpg

 

And lastly I chamfered the edges:

 

_1100569.thumb.jpg.d28176cd030ec8bc48962eeb7a5e923f.jpg

 

 

Edited by Nicholas Falzone
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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:

 

_1040492.thumb.jpg.5688e156d1717fce2a2a07751b4b0b05.jpg

 

I picked a piece with matching grain to make this as hidden as possible and ripped it to the right size:

 

_1040493.thumb.jpg.7ff381b017d40f88aaa9474b20a92fa3.jpg

 

I thought about using the CNC for this but hand tools worked better in this case:

 

_1040494.thumb.jpg.344d24774499323175484abe991e27e4.jpg

 

Getting close, I just need to do the rounded corners:

 

_1040495.thumb.jpg.0e55f3c9df1be54123a74c7b05d2f34c.jpg

 

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_1040497.thumb.jpg.9f20ade56c31742a99b1c6b1299d452a.jpg

 

And a small slot for the cable to pass through:

 

_1040498.thumb.jpg.a846614dd938cd0714b83ee059ea9da1.jpg

 

All done and ready for sanding:

 

_1040499.thumb.jpg.cf84e269cc589fd4936ac933bdc56967.jpg

 

 

Edited by Nicholas Falzone
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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:

 

_1100577.thumb.jpg.2bc13f9cdac07d1206f1af36fffd790d.jpg

 

_1090533.thumb.jpg.5d296584c8a153c2583fedf8d1efd8fd.jpg

 

 

Final version:

_1100579.thumb.jpg.b522a48c7eeb1bedf6fc684e58232862.jpg

 

I chamfered the edges to match the rest of the case:

 

P1100601.thumb.jpg.6adcb990d6d33ed358b0e600fc4f6fa6.jpg

 

I wanted the same countersunk holes and this required some creative work holding:

P1100584.thumb.jpg.ba59107a5a3931a0043717e7c582a9d2.jpg

 

P1100585.thumb.jpg.a63b780e3db5daecfd7ca73fbbd0c6f2.jpg

 

But it worked:

 

P1100587.thumb.jpg.25eb3e9f695a640b5c5835ac0f6bfa7a.jpg

 

P1100589.thumb.jpg.443371d1596f9b26fd2c9c8cee1d109d.jpg

 

Once they were all cut I drilled and tapped corresponding holes in the acrylic:

 

P1100590.thumb.jpg.ca9ce3945a45bdf93e9c0a3ee7373d09.jpg

 

P1100594.thumb.jpg.6df4e24b2e42d1aa4214563cc8b09218.jpg

 

P1100597.thumb.jpg.922626024dee36d6efb0043c863c7a17.jpg

 

Edited by Nicholas Falzone
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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:

P1100603.thumb.jpg.20e2288f304f26fd3350eaf4135f5e37.jpg

 

P1100605.thumb.jpg.3a2ea0c729f3a7bd628d39aa9158abd2.jpg

 

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:

 

P1110606.thumb.jpg.9568326fea3c477ba3327b32b88c4fde.jpg

 

P1110607.thumb.jpg.6238887b82aedf7ed7b5edfaf040fa73.jpg

 

P1110610.thumb.jpg.784fa5e698aae37177163af436de6150.jpg

 

P1110611.thumb.jpg.3b22874d35b8e1224e3f752ae7a9e7c8.jpg

 

P1110614.thumb.jpg.57ad3c5988c4ff6668bfd5cf8e51b6c1.jpg

 

It fits just like it should.  Next is programing in the corresponding holes on the acrylic side:

 

P1120622.thumb.jpg.3644ce7518ef32be2e7f06ff150dc246.jpg

Edited by Nicholas Falzone
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