Modding Log - markkleb's "Project Crossflo"

Introduction, PSU Modding, Lower Case Construction

Introduction

Overclock3D and its forums are all about community. Our roots are firmly planted in the Overclocking and Modifying scene where our members have continually shown us their technical skills and imagination through their project logs posted on our forums.

Today we'd like to bring to you one of these project logs from modder Mark Klebofski. One of his latest projects is a small form factor, custom designed case with interesting airflow. I asked him to write us an article going through his build...


Making of "CrossFlo"

My thought on building this case was to eliminate the problems associated with SFF cases.

1-Clutter
2-Lack of Hardware choices
3-Poor cooling
4-simple design (something everybody could do)

Here is a picture of one of my earlier comps a Qpack showing how it can be over filled with stuff causing very poor airflow.

qpack pic

My thought was to remove the power supply from the top of the case and put it below out of the way thus separating the heat from the motherboard and its components.

By turning the ATX motherboard sideways it allows the same rectangular shape as the Qpack/Microfly. It also allows the airflow to travel form one side to the other thus the name CrossFlo. My thought in using side to side flow was it is more efficient (flows with the axis of the cards) and has a shorter path to go.

Bigger cases have air basically entering from the front and exiting the back, but the air has to go up, over and around obstacles thus making it much less efficient.

silverstone tj09

When airflow is more efficient you need less to do the same amount of work., so the comp becomes quieter as slower speed fans can do the work of high speed ones.

Now to pick out the components that I will build this case around:

Motherboard - DFI LP 590 W/AMD X2 4200
Memory- 2 Gigs of Corsair XMS2 Pro
HDDs- 2 WD 160 GIG sata 2 in Raid0
LiteOn DVD (laptop slot-load version)
EVGA 8800 GTS
PC Power and Cooling 510 power supply
DangerDen dual 80mm Rad
DangerDen DDC pump W/ Petras custom top

It sounds like a lot to fit in a case smaller than a Qpack..


Motherboard tray and bottom half of case

First lets start with the motherboard. To add a little flash and also insulate against electricity I will make the motherboard tray out of plastic. The motherboard will be on one side and the PSU on the other.

To make fewer pieces necessary I am going to make the I/O plate as part of the motherboard tray.
To bend it just use a heat source (torch, hairdryer or heat gun). Keep the heat moving because if it stays in 1 place too long it will melt or BURN.Than I just bend it over the edge of my desk. Working with plastic is pretty easy, just remember to use SHARP tools (no dull cutters or CRACK)

bending plastic bent plastic

I am using Nylon screws and spacers to support the motherboard and PSU. There is less chance of damaging the back of the motherboard .Since I am hinging the motherboard tray and using it to support the motherboard and Hdd I have decided to make a aluminium piece for the front and back to add a little extra support.

mobo tray

mobo tray

Now to bend up a piece of metal to serve as the bottom half. Just bend it over the edge of my desk

bending bottom half

Now just attach the motherboard tray to the bottom half.

riveting motherboard


Power Supply and wiring


Power supplies have a lot of wires coming out of them. I am only going to need about half of them.

psu wiring

Also power supplies are much smaller without their cases. CAUTION DO NOT REMOVE YOUR PSU FROM ITS SHELL UNLESS YOU HAVE A THOROUGH UNDERSTANDING OF ELECTRICITY. Not to mention it instantly voids the warranty.

psu wiring

I will be using 2 HDDs and the Laptop DVD on 1 circuit. The water pump, lighting and fans will be on 1 circuit, then I need the 24 pin, 8 pin and 6 pin for the motherboard plus the wires for the voltage controls of the PSU. This means that all the rest can go. Here is what it looks like after I removed the ones not needed.

psu motherboard wiring

power connections

I like to solder the PSU wires directly to the back of the motherboard. This is a pain in the back-side and also instantly voids the motherboard's warranty, but it eliminates a bunch of extra wire and the possibility of voltage loss through added connections.

I say possibility because while on the chalkboard there is some loss in current every connection you make as long as the connections are good I believe it wont be noticeable.

custom pots pots switch

I also made a custom voltage controller so that I could adjust the voltages of the "pots" (potentiometers)


Water Cooling and HDD Rack

Since the bottom half of my case is 3 ½" tall I am going to use a DangerDen Dual 80mm rad.

80mm rad

Also I am only cooling my CPU so a Huge complicated Water loop is not necessary.
I will draw air in from the right side through the rad and than across the PSU and out the left side. I am also going to cut a 80 mm fan hole on the left side to make sure that air has an easy escape.

cooling setup

I will notch the bottom half of the case where the tubing will pass through and line it with rubber molding so the hoses aren't cut by the metal when the case is opened.
grommithole

Now to make the brackets for the Hdds and DVD. I am using Aluminum. The front piece will add structure to the bottom half of the case.
I am mounting the HDDs using rubber grommets to help to cut vibration/noise (example from previous build).

mobo tray

I saw one of these fans online and just had to have one.

flash fan

It's a 80mm fan sold by BlueGears and as it rotates it shows the temp of the air passing through. Also it helps to cool off the HDDs as well as adding a little flash to the front.

Read on to see some work on the top and front of the case...
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Most Recent Comments

08-03-2007, 07:46:47

FarFarAway
We all know Mark makes some good stuff so I thought it would be interesting to have it laid out and easy to peruse.

Cheers to Mark for writing it

Check it outQuote

08-03-2007, 08:02:26

Dav0s
ooo definately better having it there, will attract more attention aswell i expect

a great read, cheers matt/mark

ps. matt, remember the forum link at the endQuote

08-03-2007, 08:11:23

equk
Nice article

Can see someone trying to open their PSU without reading your warning and blowing themselves up tho.Quote

08-03-2007, 08:22:18

FarFarAway
Basically: unlucky if they do.

It's not a guide or anything (which we would have even more of a disclaimer on) so tough Quote

08-03-2007, 09:14:57

Mr. Smith
Nice bit of exposure for Mr. Klebofski and a decent insight into modding...

Could there be more of this type of article in the future, leaning more towards the 'how to'?Quote

08-03-2007, 09:36:45

FarFarAway
Well yes I was planning on getting a few people to do the same thing as Mark

As far as guides are concerned we do have a fair few, but if we get time then we could perhaps do some more.Quote

08-03-2007, 09:53:24

equk
I think the article is good because it's not a howto

Just from the images, you can makeout the make-up of the case and what's involved in building such a case.

I like looking at build logs esp when the end product is so good.

It's a shame perspex seems so expensive in the UK unless you're buying bulk Quote

08-03-2007, 10:29:58

markkleb
A BIG thanks to Kempez for all his help

(I bet it was more work for him to piece together the article than it was for me to build the case)

I love building things but have a hard time documenting the work.

Later on it would be fun to make a series of How-To articles. I really appreciate

for giving me a place to show my stuff.Quote

08-03-2007, 10:45:33

[Ins]
It's amazing what you can do dude! Very impressive stuff indeed!!! Quote

08-03-2007, 10:51:09

markkleb
Thank you very much.Quote

08-03-2007, 10:54:52

FarFarAway
Just don't forget to Digg it guys Quote

08-03-2007, 10:58:51

[Ins]
What does "digging" it do?Quote

08-03-2007, 11:07:03

FarFarAway
Digg has a huge readership so it exposes it to a huge online community - meaning we can share the cool stuff with loads of others Quote

08-03-2007, 11:11:48

JN
Quote:
Originally Posted by name='Kempez'
Just don't forget to Digg it guys
Yep, you can also click this icon: http://www.overclock3d.net/gfx/digg.png at the bottom of the article page to get it dugg Quote

08-03-2007, 11:46:45

Toxcity
Mark! I salute you!

One hell of a intresting mod diary.. Quote

08-03-2007, 12:01:34

mrapoc
I jsut cant get over how good it looks

Also looking at those fans as my silverstones do feck all, or those noctua fans also reviewed. Not sure which would perform best - might get a karma fan controller too Quote

08-03-2007, 12:08:08

markkleb
Thanks guys for the nice comments.

I am looking forward to making the next version so "over the top" it will give me a chance to rest finally....:sleep:Quote

08-03-2007, 12:10:40

equk
Quote:
Originally Posted by name=''[Ins
;124075'']What does "digging" it do?
I'd also like to know I know it's sommit to do with digg.comQuote

08-03-2007, 14:24:15

Dav0s
Quote:
Originally Posted by name='equk'
I'd also like to know I know it's sommit to do with digg.com
yes, the DIGG IT icon submits the page to digg, and once it is submitted you can "digg it" to make it gain more viewsQuote

08-03-2007, 14:30:43

equk
Quote:
Originally Posted by name='Dav0s'
yes, the DIGG IT icon submits the page to digg, and once it is submitted you can "digg it" to make it gain more views
Ah cool, so it's sort of another form of advertising

I've not used digg.com before tho tbh just seems like one of those new fashionable things to do Quote

08-03-2007, 16:11:21

chudley
Think it is agreat idea as it will definately attract more people, well done guys.

Quote

09-03-2007, 04:02:25

Harrythepot
ok i want to know where he got the fan with the temp on it from.

Love the projectQuote

09-03-2007, 05:04:50

JN
Quote:
Originally Posted by name='Harrythepot'
ok i want to know where he got the fan with the temp on it from.

Love the project
I believe Thermaltake sell them under the name i-flash (or something like that)Quote

09-03-2007, 08:50:07

Rastalovich
Quote:
Originally Posted by name='markkleb'
A BIG thanks to Kempez for all his help

(I bet it was more work for him to piece together the article than it was for me to build the case)

I love building things but have a hard time documenting the work.

Later on it would be fun to make a series of How-To articles. I really appreciate

for giving me a place to show my stuff.
It`s an excellent presentation and layout Kemp, really shows the work off well imo.

Have to be fair, I thought the markkleb`s project looked awesome b4, but in this form it really does both the site and the project that much more credit.

Once again, awesome work markkleb, I see little things differently each time I see it. Just spent 5mins looking over the circular fan. Quote

09-03-2007, 09:17:32

FarFarAway
Cheers Rast, took a while to get it all written up, though not as long as building it

Glad everyone is enjoying it though Quote

09-03-2007, 13:10:25

markkleb
Quote:
Originally Posted by name='Harrythepot'
ok i want to know where he got the fan with the temp on it from.

Love the project
Hey Harry, here is the fan (best $12 I ever spent)

http://www.specialtech.co.uk/spshop/customer/product.php?productid=2224&cat=0&page=

Something to consider, it dosent blow a lot of air and its not the quietest fan (not terrible either) but for "WOW" factor it does its job.

And to Rastalovich a big thanks.Quote

10-03-2007, 01:16:41

BigD
love the case, great worklogQuote

10-03-2007, 16:57:34

markkleb
Thanks Drew. I have had some luck in selling the hardware so i can start on the next version this week.

Do you guys want me to finish the Sidewinder (alum case) mod up or go in a different direction?Quote

12-03-2007, 17:16:06

pete
great article, great build.

amazing difference between the before and after fan.

whatever new mod u decide, what about considering the servo assisted motherboard tray option. think u were trying to source before?Quote

15-07-2007, 06:04:22

TJS
Thats a great job you did, Markleb, liked the idea with the dual radiator on the inside instead of on the outside where it sticks out like a sore thumb. Very smooth looking, thats a case anyone and everyone would want!

TJSQuote

15-07-2007, 08:15:57

PV5150
Yeah he is a great modder for sure. I'm in the process of getting something sortedf for this as we speak Quote

15-07-2007, 09:26:08

Toxcity
Quote:
Originally Posted by name='PV5150'
Yeah he is a great modder for sure. I'm in the process of getting something sortedf for this as we speak
Will be looking forward to this Mr PV! Quote

15-07-2007, 17:14:55

markkleb
I just got a email saying someone responded to this thread, lol (seems like so long ago, wow time flies)

Due to a lot of personal stuff I have been out of modding (and internet stuff too) for quite a while. I think I can get started again.

So, Hello all

I just noticed there are 21935 NEW posts since my last visit, better get reading.Quote

15-07-2007, 17:16:02

llwyd
Quote:
Originally Posted by name='markkleb'
I just got a email saying someone responded to this thread, lol (from almost a year ago, wow time flys)

Due to a lot of personal stuff I have been out of modding (and internet stuff too) for quite a while. I think I can get started again.

So, Hello all
oh my god

its markkleb!!!


we've had 'where on earth is markkleb' threads hahaQuote

15-07-2007, 17:16:13

Ham
Good to see ya again Quote

15-07-2007, 17:20:35

markkleb
Hello guys, I need to switch notification to my new email so i know whats going on.

Hope ur all doing well.Quote

16-07-2007, 05:24:29

FarFarAway
Hey mate, good to see you again!!! Quote

16-07-2007, 06:58:04

PV5150
Hi markkleb It's so nice to see you back again, we were about to send out the missing persons unit after you. Please don't go vanishing again...or look out Quote

03-08-2007, 12:19:56

K3Y
Nice little read and the end result is amazing! Looks so goodQuote

03-08-2007, 18:24:07

markkleb
Thanks K3Y and welcome to OC3D.

Thanks to everyone else for the hellos.

I am trying to finish another one for PDXLAN 10 at the end of August. Its another 500 man LAN and probably my last for quite a while.

I have gone nutts on the new one and like AI and Kempez recommended its made from aluminum. I threw in some CarbonFiber as well for giggles, I call it CrossFlow Xtreme.

Here is the link to its Build log

http://forum.overclock3d.net/showthread.php?t=11526Quote

10-08-2007, 01:32:06

markkleb
I had a chance to read over the nice article about CrossFlow (Thanks again Kempez) and forgot this pict. Its hard to realize how small this comp actually is but here is a pict showing it sitting next to a PS box.

http://i101.photobucket.com/albums/m.../2nd_place.jpgQuote
Reply
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