Metal tool case computer

[InertiaSelling]

 

 

 

Spoiler

 

 

Hi. This topic was originally created to document a custom case build project. Since an old tool case is now sitting on my desk outputting this page to my monitor, I consider it not to be a project anymore, which is why this topic has been moved to the "build logs" section. Though this OP has undergone a complete facelift to become cleaner, less descriptive and more condensed, its original content can still be found below.

 

Objectives

• Smaller size: Having a 52 liter masterbox 5 on my desk forced me to shift everything to the left, which was a complete waste of space. I needed something that would fit under the old hardware shelf on my right.
• Rusty appearance: As a huge Bethesda fanboy, I wanted my case to look like it was cobbled together like the Fallout raider armors or the pipe pistol.
• Experimenting: I had never done any DIY work in my life. My hands are full of cuts because I had never used them for anything else than typing on a keyboard.
• Bragging rights: I felt like a pompous asshole for giving a name to my first build, even though it was just some parts I had bought, then screwed and plugged together. It had to be solved.

 

Hardware

• KFA2 GTX 1060 6GB
• Ryzen 5 1500X
• Gigabyte GA-AB350M-gaming 3
• 16GB of DDR4-2400 Crucial ballistix sport
• Cooler Master G550M
• Crucial mx300 525GB m.2
• 300mbps tp-link PCIe wifi adapter

Other materials

• An old radio from a garage sale;
• Some old buttons from garage sales;
• A modular, translucent schneider electric power switch from a garage sale;
• A sheet of acrylic;
• Self-tapping screws, bolts and nuts;
• Deepcool RGB 350 with two LED strips;
• An old PC case from a compaq presario;
• Scrap steel from an old hi-fi system;
• An old metal tool case.

No fancy tools were used. Maybe they were faulty, maybe I'm just plain dumb, but the dremel woudln't cut anything, the reciprocating saw bent the metal instead of cutting it, and the (glorious) angle grinder only had a very thick and unprecise grinding wheel. As a consequence, most things were done using a power drill, a big metal saw, a smaller metal saw, some screwdrivers, two vises, a mallet, some files, some sandpaper, and various pliers.

 

 

Actual build log

 

Here's the original first post of this topic, followed by all of the updates, so that everything can be read at once. The pictures are mere screencaps though, since every step has been recorded, then edited to make the build log video below. Whichever you choose, I hope you enjoy it as much as I enjoyed making them.

Spoiler

Hi. After a few weeks of planning, I've been working on this project for a few days now, and I tought it was time to start sharing my progress here.

 

My goal is to rebuild my computer in this metal tool case. I mostly play Fallout, which is why I love its rusty look so much. I want my PC to be the computer equivalent to the pipe pistol. If I succeed, it will have an acrylic window on the top, the air intakes (and perhaps exhaust as well) will be hidden behind some speaker grids from old radios, and there will be an ammeter as well as a voltmeter somewhere whose indicators will move when the computer is turned on. Also, I will add some magnetic LED strips to illuminate the interior.

 

Here is a drawing of what it should look like from the top when I'm done.

 

I will be using this expensive thing from schneider electric as a power switch. Though I have only tested its ability to turn a computer on and off as of now, I should be able to get the LED behind the switch to light up when the computer is turned on, which will add a nice, industrial touch.

 

The PCIe and motherboard I/O mount was taken from an old PC case.

 

It was then cut a bit.

 

The steel from the old PC case got recycled to support the motherboard.

 

It was cut on the angles, then bent 90° twice on each side. The second bend will allow it to be screwed to the bottom of the case.

 

Most of the cables should be under this piece of metal, so a few cuts were made for cable management. They still need to be filed a bit more, but it's not an absolute necessity, as they are located on the sides and below the motherboard itself, as shown by the mounting holes.

 

The motherboard / extension cards mounts has then been attached to the black metal piece.

 

The tool case was then cut to accomodate the mount.

 

This is what the project looks like as of right now.

 

I still have a lot to do, but I feel like the hardest part is done. Even if I fail to make a functional and / or nice-looking case, I will have learned a lot in the process.

 

_____________________________________________

Update 1 : Top window cut

 

The acrylic panel will be mounted on top of the case using screws, a bit like tempered glass panels are often installed. Consequently, enough space had to be left for the screws. This will also allow the LED strips to be magnetically attached under the metal frame, which should make them invisible from any angle.

 

First, the metal had to be drilled through.

 

It was then (tediously) cut along the lines using a (tiny) metal hand saw.

 

The frame was then filed, as it was sharp and not completely straight.

 

Here is the current state of the project.

 

_____________________________________________

 

Update 2 : bolts and nuts

 

Nothing spectacular today. The black piece of metal that will support the motherboard was already bolted to the motherboard/PCIe mount. I chose to attach both to the case to prevent anything from bending.

 

First, the mount and case were drilled through twice.

 

A larger drill bit was then used to prevent the bolt heads from sticking out too much.

 

The same process was repeated in order to attach the black piece to the bottom of the case.

 

It took some time though, as the nuts were very difficult to access. I ended up with a few unnecessary holes, but they're on the bottom, so it's not too visible.

 

This is what it looks like now. I might add a few decorative bolts next to these two, as they look quite lonely. Not sure I'll bother though, since this part is meant to face a wall.

 

_____________________________________________

Update 3 : fans and PSU

 

Today, the PSU mount was made by simply drilling through a side of the case.

 

The holes had to be filed, as the didn't exactly match those on the PSU.

 

A PSU can now be secured in the case.

 

Holes were also made for the fans.

 

As expected, the intake one can be easily mounted.

 

The exhaust fan, on the other hand, will have its top part right under the metal frame on the top, so that is doesn't interfere with the motherboard. Consequently, its two top holes won't be used. I doesn't matter much though, as two plastic rivets are enough to secure it in place.

 

Before cutting the intake and exhaust vents, the front vent cover had to be screwed in place, so that its exact shape could be reproduced under it. Unfortunately, the locks on the case interfered with it, so it had to be cut a bit. The result doesn't look very good, but I'll find a way to fix that later.

 

This afternoon, I'll make the intake and exhaust vents. I'll probably use a power drill, as this is both faster and easier than hand-made cuts, and it won't be visible anyway. Hopefully, I'll have enough time to do a few more things. Next update in the evening.

 

_____________________________________________

Update 4 : unsatisfactory

 

At first, I wanted to drill a dense array of holes.

 

It took much longer than I thought it would, and when I was done, I realised it would restrict the airflow a lot.

 

So I decided to remove the whole circle, but I didn't have the appropriate tools. It took the rest of the afternoon, and will still have to file it a lot, because it's ugly.

 

Maybe I won't bother, because it's not visible from the outside nor from the top. Maybe I will, because it makes me sick.

 

I'm displeased. I'll have to work a lot faster tomorrow if I want this project to be finished before the end of my summer holiday. Also, I have a paper to write. Fuck.

 

_____________________________________________

Update 5 : More cuts

 

First, I decided to file my messy cut from yesterday. It will be sandwiched between the cover and the fan, but still, I felt like it had to be done.

 

Then a cut was made in the back for the PSU exhaust and power cord. Again, the metal had to be drilled through first, so that the blade could fit.

 

At this point, I could probably rebuild my computer in this case. The PSU would suffocate and the overall airflow would be unsufficient, but I could. It feels like a huge step. Next update this evening.

 

_____________________________________________

 

Update 6 : PSU YES

 

I'm done with the PSU area.

 

First, a large square vent was cut where the PSU intake would be (forgot to take pictures of this though). Then a piece of drilled steel was stolen from an old side panel.

 

It was bent 90°.

 

Measurements for the next cut were taken directly on the case, so that the bent piece of steel wouldn't cover the PSU exhaust hole.

 

Three holes were drilled next to its edge so that it could be bolted to the case without interfering with the PSU.

 

Two of the PSU mounting holes were drilled in the small part right after the angle, so that it could be attached there as well. A little bit of filing was necessary, since the PSU screws were almost as big as the drill bit that was used.

 

This is what the PSU area looks like now. The PSU can now be mounted and plugged in, take air from the outside, and exhaust it at the back. Also, it doesn't look awful while doing so, which is almost as important.

 

And here's the current state of the project.

 

I still have to drill an exhaust vent where the second fan will be mounted, install the power switch as well as whatever would fit on the front next to the handle (fake buttons, voltmeter, etc.), and then install the acrylic panel. This is the end of my to-do list though. Once that will be done, everything will only have to be cleaned before I can begin to cram my components inside.

 

_____________________________________________

Update 7 : almost done

 

First, the exhaust vent was cut.

 

A metal plate was then made from the steel casing of an old hi-fi system. It got filed until it looked nice enough.

 

The metal piece was bolted to the vent.

 

Here's what it looks like with a 120mm fan installed.

 

The power switch hole was also drilled today, with completely inappropriate tools, as always.

 

The power button got wired as well. The LED doesn't light up though, so I guess I'll remove the LED module so that the LED strips can backlight it a bit.

 

Here's what it looks like now.

 

I also drilled a hole right under the power switch in order to use the hole in its back piece to bolt it in place. It doesn't work though, so I guess I'll try to find o-rings that will get sandwitched between the actuator and the switch and hold everything together. If I manage to do this, I'll use the hole under the power button to make my infrared receptor stick out a bit. I do need to do that, since I use a cheap LED system.

 

Next update tomorrow.

 

_____________________________________________

 

Update 7 : done (pretty much)

 

Surprisingly, the o-ring actually managed to secure the power button in place.

 

A few switches were desoldered from some old radios, along with their entire mechanisms.

 

Large holes were drilled in order for them to be installed.

 

The acrylic panel was marked and cut using a saw.

 

It was then bolted to the case and filed, as it was a bit too large.

 

Metal and acrylic dust was removed with a vacuum cleaner, a hair dryer and a toothbrush.

 

At this point, the transplant could have been performed, but I decided to eat first.

 

A ghetto ankle strap (a simple wire attached to the ground pin of a wall socket) was used to prevent static discharge from damaging the components.

 

Quite unsurprisingly, I ran into a lot of issues.

 

First, the PSU I used as a template didn't have any protruding parts, whereas mine did. I had to make a cut I hadn't planned to make.

 

Then, the cables wouldn't run through the cable management holes I hade made, so I had to disassemble the switches and the motherboard tray. Indeed, the motherboard ended up on top of the GPU cable hole, so I didn't use it in the end.

 

Also, the standoffs really weren't where they were supposed to be. A few millimeters are enough to prevent the screw from sliding in. Eventually, the template (short) mATX motherboard had to be used again in order not to damage mine, and the standoffs were adjusted. All of the screws were succesfully used to secure the motherboard in place, though not all of them were perfectly straight.

 

The two switches' positions had to be changed because they interfered with a USB header. A little bit of electrical tape was added to prevent short circuits.

 

Everything was finally installed inside the case. Unspeakable (linus-style) things had to be done to both of the expansion cards due to incorrect measurements.

 

The computer was then powered on. After an "out of range" error because only one monitor was used instead of the usual two, everything worked correctly.

 

The plastic film was therefore removed from the acrylic panel, which got installed shortly afterwards. It has a few scratches, but nothing terrible.

 

The LED strips got installed as well, once the computer was placed on a shelf to increase usable space on the desk.

 

The final test was to use it for some time. I chose to write this update, and at this point, nothing too bad has happened. The cable management is terrible, both inside and outside of the case, and the intake fan has been installed backwards, which forces me to use the machine with its lid open as an intake vent. Hopefully, I'll manage to fix all of that tomorrow, tidy up my desk, and enjoy my new setup. What I won't be able to fix, though, are the cut tabs on my cards, as well as the poor alignment of the rear I/O. These are my only regrets.

 

Overall, and unless something shorts out overnight, this project is a success. I should be able to edit the build log video on this nice-looking machine, instead of editing a "what not to do" video on my old laptop. It is now 3am in France, so I guess I'll shower and go to bed. Thanks for your support.

 

_____________________________________________

 

I have no idea what happened to the music. It's awful from 1:52 to 4:54 and 8:52 to 14:45 especially on the left channel. I didn't manage to fix it, so I would suggest muting it and playing whatever music you enjoy instead (don't miss the conclusion though). Sorry.

 

[idontknowwhy]

majestic

[Billy_Mays]

Pretty good and that was a really good idea reusing the motherboard tray for mounting it it's a cheap way to do that and I can use that for my next case thanks for that idea

[InertiaSelling]

@idontknowwhy ty

 

@Billy_Mays I would recommend keeping the actual tray attached to the mounting piece, as getting it aligned correctly with a supporting piece such as mine can cause headaches and nausea. For example, my standoffs are 7 to 8mm, but the standoffs in the old OEM PC case are only 5 or 6mm, because the mounting piece is in fact meant to be attached a bit lower, and that's hard to counter with hand tools.

[Billy_Mays]

2 minutes ago, InertiaSelling said:

@idontknowwhy ty

 

@Billy_Mays I would recommend keeping the actual tray attached to the mounting piece, as getting it aligned correctly with a supporting piece such as mine can cause headaches and nausea. For example, my standoffs are 7 to 8mm, but the standoffs in the old OEM PC case are only 5 or 6mm, because the mounting piece is in fact meant to be attached a bit lower, and that's hard to counter with hand tools.

I have a Zalman Z1 Neo but the standoff holes are stripped since the previous owner didn't care for it much

[InertiaSelling]

@Billy_Mays Please PM me if you do make a custom case someday, I'd love to see more of those.

[Billy_Mays]

12 minutes ago, InertiaSelling said:

@Billy_Mays Please PM me if you do make a custom case someday, I'd love to see more of those.

Ok 

[Orangeator]

Wow! This is going to look so awesome. Can't wait to see the finished project. Won't be surprised if this turns out better than Luke's Fallout Bomb Build. Haha.

[rodrosenberg]

Sweet project! 

[InertiaSelling]

Update 1 : Top window cut

 

The acrylic panel will be mounted on top of the case using screws, a bit like tempered glass panels are often installed. Consequently, enough space had to be left for the screws. This will also allow the LED strips to be magnetically attached under the metal frame, which should make them invisible from any angle.

 

First, the metal had to be drilled through.

 

It was then (tediously) cut along the lines using a (tiny) metal hand saw.

 

The frame was then filed, as it was sharp and not completely straight.

 

Here is the current state of the project.

 

@idontknowwhy @Billy_Mays @Orangeator @rodrosenberg Would you like to be tagged whenever I update this topic ?

[Billy_Mays]

4 minutes ago, InertiaSelling said:

Update 1 : Top window cut

 

The acrylic panel will be mounted on top of the case using screws, a bit like tempered glass panels are often installed. Consequently, enough space had to be left for the screws. This will also allow the LED strips to be magnetically attached under the metal frame, which should make them invisible from any angle.

 

First, the metal had to be drilled through.

 

It was then (tediously) cut along the lines using a (tiny) metal hand saw.

 

The frame was then filed, as it was sharp and not completely straight.

 

Here is the current state of the project.

 

@idontknowwhy @Billy_Mays @Orangeator @rodrosenberg Would you like to be tagged whenever I update this topic ?

We can follow the topid and its looking nice

[InertiaSelling]

Just now, Billy_Mays said:

We can follow the topid and its looking nice

Oh. I hadn't noticed this feature. My bad.

[Billy_Mays]

Just now, InertiaSelling said:

Oh. I hadn't noticed this feature. My bad.

Its fine all of us are here to help each other out

[idontknowwhy]

2 hours ago, InertiaSelling said:

Update 1 : Top window cut

 

The acrylic panel will be mounted on top of the case using screws, a bit like tempered glass panels are often installed. Consequently, enough space had to be left for the screws. This will also allow the LED strips to be magnetically attached under the metal frame, which should make them invisible from any angle.

 

First, the metal had to be drilled through.

 

It was then (tediously) cut along the lines using a (tiny) metal hand saw.

 

The frame was then filed, as it was sharp and not completely straight.

 

Here is the current state of the project.

 

@idontknowwhy @Billy_Mays @Orangeator @rodrosenberg Would you like to be tagged whenever I update this topic ?

looks great so far. are you going to repaint it or leave it the color it is? 

[InertiaSelling]

@idontknowwhy I hesitated for a while, but I think I'll keep the rusty look. Maybe I'll paint it if it doesn't look good enough when I'm done.

[InertiaSelling]

Looks like I will only be using the voltmeter and not the 200mA ammeter. Actually, I knew 200mA was much less than what a molex connector can provide, but I had to check. Wasn't expecting the smoke though.

 

[InertiaSelling]

Update 2 : bolts and nuts

 

Nothing spectacular today. The black piece of metal that will support the motherboard was already bolted to the motherboard/PCIe mount. I chose to attach both to the case to prevent anything from bending.

 

First, the mount and case were drilled through twice.

 

A larger drill bit was then used to prevent the bolt heads from sticking out too much.

 

The same process was repeated in order to attach the black piece to the bottom of the case.

 

It took some time though, as the nuts were very difficult to access. I ended up with a few unnecessary holes, but they're on the bottom, so it's not too visible.

 

This is what it looks like now. I might add a few decorative bolts next to these two, as they look quite lonely. Not sure I'll bother though, since this part is meant to face a wall.

[Billy_Mays]

Looks pretty good now, are you going to add fans on the bottom of it (below where GPU would be)

[InertiaSelling]

@Billy_Mays The fans are the black blocks with arrows on this drawing.

 

 

There will be one next to the GPU, but it will not be facing it directly, as it could hurt the overall airflow. Besides, I need somewhere to put my power switch and voltmeter, as well as a few decorative buttons. Both fans should be 120mm, but I'm not 100% sure they'll fit, so I might have to use smaller ones.

[Billy_Mays]

1 hour ago, InertiaSelling said:

@Billy_Mays The fans are the black blocks with arrows on this drawing.

 

 

There will be one next to the GPU, but it will not be facing it directly, as it could hurt the overall airflow. Besides, I need somewhere to put my power switch and voltmeter, as well as a few decorative buttons. Both fans should be 120mm, but I'm not 100% sure they'll fit, so I might have to use smaller ones.

Ok looks pretty good to me and air flow looks to be great

[InertiaSelling]

Update 3 : fans and PSU

 

Today, the PSU mount was made by simply drilling through a side of the case.

 

The holes had to be filed, as the didn't exactly match those on the PSU.

 

A PSU can now be secured in the case.

 

Holes were also made for the fans.

 

As expected, the intake one can be easily mounted.

 

The exhaust fan, on the other hand, will have its top part right under the metal frame on the top, so that is doesn't interfere with the motherboard. Consequently, its two top holes won't be used. I doesn't matter much though, as two plastic rivets are enough to secure it in place.

 

Before cutting the intake and exhaust vents, the front vent cover had to be screwed in place, so that its exact shape could be reproduced under it. Unfortunately, the locks on the case interfered with it, so it had to be cut a bit. The result doesn't look very good, but I'll find a way to fix that later.

 

This afternoon, I'll make the intake and exhaust vents. I'll probably use a power drill, as this is both faster and easier than hand-made cuts, and it won't be visible anyway. Hopefully, I'll have enough time to do a few more things. Next update in the evening.

[Billy_Mays]

Pretty good so far

[Orangeator]

Looking good!

[InertiaSelling]

Update 4 : unsatisfactory

 

At first, I wanted to drill a dense array of holes.

 

It took much longer than I thought it would, and when I was done, I realised it would restrict the airflow a lot.

 

So I decided to remove the whole circle, but I didn't have the appropriate tools. It took the rest of the afternoon, and will still have to file it a lot, because it's ugly.

 

Maybe I won't bother, because it's not visible from the outside nor from the top. Maybe I will, because it makes me sick.

 

I'm displeased. I'll have to work a lot faster tomorrow if I want this project to be finished before the end of my summer holiday. Also, I have a paper to write. Fuck.

[InertiaSelling]

Update 5 : More cuts

 

First, I decided to file my messy cut from yesterday. It will be sandwiched between the cover and the fan, but still, I felt like it had to be done.

 

Then a cut was made in the back for the PSU exhaust and power cord. Again, the metal had to be drilled through first, so that the blade could fit.

 

At this point, I could probably rebuild my computer in this case. The PSU would suffocate and the overall airflow would be unsufficient, but I could. It feels like a huge step. Next update this evening.