BFG case mod Work Log (56K, go away =)

[Geno]

OK. I Officially start tomorrow when UPS gets here with my parts. 48 water cut parts from maximum Industries in Dallas TX, most in 1/8" aluminum, but some in 1/16", 3/16", and 1/2" aluminum as well as some parts in 1/8" plexiglas.

This will be a custom case with a BFG (the nVidia powered video card maker) theme done in Polished Alu and tinted Plex. Some of the features are:

100% polished to a mirror inside and out.
100% custom case, (welded, radiused corners)
15 inch BFG logo "spinners" on both hatches/side covers.
w/c everything, including (time permitting) a pair of 7950 GX 2's
All water lines rigid copper bent to shape and chromed with compression fittings.
Custom 5" dia rez with plex hatches (cools the pair of windowed raptors also).
Animatronic mini gun (chromed 6 barel gatlin gun ala Terminator) that is controlled via windows interface. The gun is 4.25 inches in dia and will extend 3 inches from the case/retract into the case with a special hidden hatch.

And a bunch of other junk lol. I will try to post images as it progresses, but time is VERY short for Qcon. Will be a show stopper...or suck, stay tuned

Geno
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[EscapeYourMind]

one word.. fire

lol, I just had to say it. Either way looking forward to seeing the process of this mod, should be awesome.
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[frogle79]

Like I said elsewhere, can't wait and good luck. I wanna see some kick ass stuff!!!
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[Achilles0]

i wont stop touching myself until its done
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[Geno]

OK guys, some teaser sketchs of the BFG mini gun that will be opperated via windows and slide out the front of the case.





All text and no images/graphics is no fun after all.
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[frogle79]

Just make sure it goes click click click BBBLLLLPPPPTTTPPPPPOOOOOMMMMMMMM!!!!! Oh yeah, no rounds right? YEAH baby good stuff!!
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[Geno]

I designed it with a butane powered 2 inch "bullet torch" in the begining but THE MAN said "No open flame or combustable gas in the convention center". Creative opression sucks.
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[EscapeYourMind]

Ya its such a shame.
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[Geno]

[Geno]

UPDATE:

Got the welding Jig/fixture for the case done and ready to burn, will be welding the case together today. Got the rez brackets carved, and ready to weld also, as well as the top blow hole ducts/fan mounts.

I will have a few construction pics this evening. I need sleep, and a bath. No time lol.














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[Geno]

Special thanks to Mr Slacker for letting me just email him the pictures for posting...I miss having him here working with me though

We hit a snag with the welding. Had it all assembled on the jig/fixture, got the front/top/bock part bent and clamped onto the jig also. While tacking it all together with the TIG there were problems that we think may have been polishing compound residue (though the parts were well washed) so for running the bead on the bottom my buddy Louie busted out his wire feed and it laid down a nice bead but splattered like hell. We flipped the case over and it looked like CRAP on the inside. All that pre-polishing the inside
to save work ended up causing a LOT more work in the long run.

Spent the whole day shaping the edges of parts and polishing. Mostly the smallet parts like the mini gun rings, motor mounts (for the animatronic mini gun), and some of the covers etc. My arms feel like they are gonna fall off. The wife laid down the LAW yesterday and said if I didnt sleep at least 6 hours I would be sorry. She spent most of the day today in the shop sanding and cleaning edges on the metal parts =)


Above is the raw part, then after a little time with a file and lots of sanding



This shows how a 3/16" part looks after waterjet cutting



Above is a close up showing the chamfer in a hole for a gun barel



This shows a gun ring and a 1/16" fan bracket with its first round of polishing, or what I call pre polish. This makes any areas that need more work stand out.


G
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[frogle79]

Looking shhwweeetttt as usual Geno. Looks like the guys you had cut everything did a hell of a job.

BTW I feel like a jackass, I looked at the jig with the case parts all clamped to it and thought, "DAMN how in the hell is he gonna get all the wood out after he welds it together?" Then I saw that the bottom wasn't attached. DUUUHHHH. I must have been tired last night.

[Geno]

Your not too far off on the jig. If you look close at the last welding picture you can seel ittle bits of what is left of it on the floor and the hammer I used to bust it up =)

And also right about the wives. She just said if you don't get it done, it's not the end of the world. We got a late start. Now I am just working till I drop, sleeping a few hours, then rince and repeat.
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[Geno]

**UPDATE**

The bad weld crap (slag) inside is proving to be a pain in the ass. Lucky for me my wife is tiny and has been half stuffed into the case with a dremel tool chipping away at it for 8 hours now...

I have the outer seam radius grinding about 3/4 done. The clock refuses to slow down, and it will be close, but we might make it for Qcon. I ordered a pair of windowed Raptors and a pair of BFG 7950 GX2's from newegg yesterday.

The guys over at Danger Den are busting their hump to get the proto type coolers done for the 7950's but they don't think they are gonna make it. The good news is they are sending one of their new pumps, the CPU and chipset blocks, and one of their new 120mm dual Stealth radiators.

Hit another snag on the water jet cut parts. I drew in .093" holes so I could tap them for 4-40 alu flat head socket screws...and the holes are all way too big. There goes $40 dollars worth of specialty screws down the drain, and I am without screws now. JOY. I rechecked the drawings, my shit was right lol.

Mr Slacker will be posting pictures later. Back to my EZ Bake oven/shop =)
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[Geno]

7:00 AM...this morning is a make it or break it trip BACK to the welder. I am having a bead welded on the interior seams of the case. The weld through from the initial welding just looked trashy, even though my wife gave it her best shot for most of a day with the dremel.

also, cause the weld was so fat the radius had to be larger than normal, and I popped the welds in several spots. If it looks too bad, or doesnt take, I am going to have to make a new set of side panels and start over...and there just won't be time to get it done for the con.

Wish us luck =)
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[MrSlacker]

How did it come out?
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[EscapeYourMind]

Albert, where are my promised pictures...Geno said you would be posting some.
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[MrSlacker]

[Geno]

OK, sorry for not sending pictures. My wife did get a "nice" one of me passed out face mashed into the side of the case, snorrrrring away. She just turned off the grinder, pointed the fan at me, and turned off the big overhead lights lol.

For the 3 of you interested...the welding went quite well, and though I now have to regrind the entire case, I am thrilled. More good news, the guys at DangerDen have pulled it out and the 7950 GX 2 video card water blocks shipped out today. BIG props to those guys for "getting it done".

Back to the shop for me, will try to update with images soon.

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[Geno]

Here you go guys, in no particular order, and no comment for now...it's 4 AM and i am whipped.



















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[frogle79]

AAHHHH I just love how polished alum looks. My personal taste has always been that, I hate chrome. Looks like you got a decent 2nd job on the welding. The rad holder looks good too, (I'm asuming those are the rad holder) I was wondering where you were gonna put it. I bet cutting the holes in the case was fun.
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[EscapeYourMind]

looking good so far.. hopefully it will make it for qcon.
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[MrSlacker]

damn thats sexy... now i wonna see pics of the gun!!!


keep up the good work dude!!!!!!
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[MrSlacker]

Here are some new pics from Geno. He has been busting his ass off.












Its coming along very well, but time is running out. YOU CAN DO IT!!!!!!!!!!!!!!!
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[EscapeYourMind]

looking good so far
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[V4VanGelder]

awesome case! It's gonnabe awesome! nice work with the TIG, hope i can still do that, haven't welded in almost a year.
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[Geno]

[Geno]

case is polished...looks orgasmic ...

Just this minute bolted the mini gun together for the first time...sweetness.

Pics soon.
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[Geno]

Pictures:

The first is of the case itself, all welded with primary polishing done. Still needs the last stage which is the one that gives it depth, but I do that one last.




This is a view of the top radiator ducting, the inside of the holes/duct still has to be sanded and polished.




A shot of the gun main barel assembly (sorry about the finger prints lol)




Another shot of the barrel assembly, different angle...and a lot of LAB reflections lol. You can just see the custom rez on the left.




Here is the rez itself, also reflected in the case. Still some polishing to do on it, but almost there.




Im gonna take a handful of Advil and get back to work...nap sure would be nice right about no...snorrrrr
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[frogle79]

KEEP IT UP!!! It looks kick ass!! Your making me wanna tear my rig apart and polish it up damnit.
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