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  1. #1
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    DarthBeavis Project: Trek

    This project started LAST year . . .PAX mentioned was PAX Prime 2009
    This project will be themed on the utility case a Star Trek Engineering away team might take on a mission. Technology featured in this build will include Nvidia's 3d Stereo graphics for the most immerse gaming short of a holodeck. The build will contain two mini-itx based systems for true head-to-head gaming. The project is a join venture between BoxGods (a.k.a. Geno) and Out of the Box Mods (a.k.a. me). Our goal is to have it premier at QuakeCon (Nvidia has booth space reserved for it) then next travel to PAX.

    Sponsors:
    - Nvidia (3d monitors, glasses)
    - Danger Den (CNC, laser, design services, I think I bought all the water-cooling parts retail for this project except GPU blocks)
    - Crucial (Ballistix Tracer ram and SSD hard drives)
    - Performance PCs (tons of stuff)
    - Mountain Mods (thanks for helping get materials on short notice Ben!!!)
    - BoxGods (aluminum boxes and tons of design services)
    - Asus (motherboards? and GPUS)
    - I wanted to fit FrozenQ reservoirs in but the space is so small he would have to make really small ones. I do not know if he will have time. Anyway, he still deserves a shout out.

    Geno, after months of work and more than one sleepless night and shower less day has the drawings finished. I received the aluminum boxes Friday, then traveled to Danger Den Saturday. Jeremy, the CEO of DD, was kind enough to give up his entire day to draw the holes for the case where I needed them and then use one of their CNC mills to cut the holes. This week they will laser cut the acrylic parts as well. Today I ground the slag off the boxes and radiused the edges (Geno already has some of it done so I would know what result to shoot for). This is my FIRST time working with metal so please keep that in mind when commenting. I still have to do use the Scotch Bright finishing sander attachment (this round was with a number 80 flap attachment). Tomorrow I will start the polishing . . .w00t

    Drawing (not complete):



    CNC Mill:



    After mill:


    Grinding (Geno I do listen to your safety nagging):






    Guess I have a date with a file and sandpaper tomorrow as well . . . .maybe polishing on Tuesday?

  2. #2
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    Here is a different perspective with more details drawn in:

  3. #3
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    Did what I could metal-working on teh boxes, but got some pros to help get it rightly polished up. here is the center box. The other two are already at the painter who will paint the inside metallic teal then clearcoat the inside and outside of the boxes. I might also have them paint the PSU








  4. #4
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    Moar Shiney . . .also filed the corners of the reservoir hole so it will sit flush. It will have one of the new billeted aluminum face plates polished to match the case




    Thanks to Asus and Crucial for sponsoring hardware:



  5. #5
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    Decided to get some painting done. The pump and rads really will not be visible but I wanted to at least have them reflect some light to maybe help light up the 'nacelles' or laminated acrylic layers between the boxes




    Geno says I will have some sanding and polishing of the edges of the acrylic pieces when they get here so I stocked up on compounds (also need to polish the knobs . . .errr, that did not sound right . . .uh handles for adjusting the monitors)

  6. #6
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    Got the PSU put together after painting (finally a silver Silverstone) . . .then started violating my diet by consuming a steady stream of gin and tonics . . .


    Got the boxes back from painting:



    Wish I had the pump painted teal as well:


  7. #7
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    got the acrylic pieces in from Geno . . .first peeling off all the paper. tomorrow starts sanding and polishing.



    to give you an idea of how many parts:

  8. #8
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    sanding away (batch sand then go back and wet sand with finer grit individually):



    Sniipe look what I have in the backround

  9. #9
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    fully polished black piece next to sanded black piece (only 100 or so more to go)


    That is on the buffing wheel using blue compound and a five sewn wheel
    Polished ALL day long and still went to the gym. Special thanks to my buddy John (SoundEvolution) for spending the last two days sanding with his orbital while I wet sanded and polished. After the project is done I will post some videos of parts of the project.

    Here is a test assembly of the center box and one of the side boxes. I got the order wrong as the black layer with the radiator mounts goes next to the bigger center box not the outside box. So far, looking good. I will clean the acrylic up well before final assembly.






  10. #10
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    Yes I have some nice 6" UV cathodes and a load of UV LED strips to play with. lights will be remote controlled
    Test fitting the wheel assembly (will use different mounting hardware of course


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