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Windows 7: Got a New Case!

01 May 2014   #61
Lady Fitzgerald

Win 7 Ultimate 64 bit
 
 

Thanks, Jack. If I decide to get a different PSU (which is looking likely), it will be the AX760 (non-I) and I've pretty much decided not to cut out the grill in the floor of the case. I've done a bit more work today; more on that later.


My System SpecsSystem Spec
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03 May 2014   #62
Lady Fitzgerald

Win 7 Ultimate 64 bit
 
 

I've gotten some more work done. I decided to use a fan hub to provide an easy point to disconnect and reconnect the side fans when I remove the left side cover. I have something similar for my present case and it worked out great. I figured out the stock fan cables are long enough so I can plug directly into a hub. This is the smallest hub I could find:

Got a New Case!-img_0003.jpg

I needed only two connectors and I'm too anal to deliberately leave two unused so I fed the little jewel through my little bandsaw and ended up with this:

Got a New Case!-img_0008.jpg

There was another little problem as well. When putting more than one fan on a MOBO PWM connector, only one fan can be sending the rpm signal; otherwise the MOBO gets all confused. Unfortunately, the hub had the rpm pin for all four fans connected so I scraped off a part of the rpm trace from the PCB between the first and second plugs. I could have just snipped off that pin but this looks less rednecked:

Got a New Case!-img_0009.jpg

One thing I learned about these fan hubs on my current case is they can easily get damaged if one forgets to unplug the fan cable before completely removing the side panel (don't ask how I found out ). I found that dabbing some brush on nail glue around the perimeter of each socket will reinforce them enough to help protect them small yanks. Nail glue on nonorganic surfaces takes forever to dry so I have the hub set to one side to dry.

On my current rig, I fastened the base of the hub to the back of the case using screws through standoffs the same length as the thickness of the acoustic foam they pass through. I'm going to do the same here but on the floor of the case where it will not get in the way (like the one in my present case does).


My System SpecsSystem Spec
03 May 2014   #63
Layback Bear

Windows 7 Pro. 64/SP-1
 
 

I'm watching and learning.
Fan hubs are great things.
Does that fan hub have a 12v input?
My System SpecsSystem Spec
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03 May 2014   #64
Lady Fitzgerald

Win 7 Ultimate 64 bit
 
 

Quote   Quote: Originally Posted by Layback Bear View Post
I'm watching and learning.
Fan hubs are great things.
Does that fan hub have a 12v input?
Not exactly. It connects directly via a cable to a MOBO PWM fan header and the fans get their power from there. The hub in my current rig, however, runs directly on 12v via a 4 pin Molex connector. The PWM case fan headers on my MOBO can handle up to 1A and the PWM case fans I'm going to use draw only 0.30A each so I can easily put two fans on a single header (I could probably get away with three but I don't like to push my luck and, besides, I need only two fans on a header anyway).
My System SpecsSystem Spec
04 May 2014   #65
Lady Fitzgerald

Win 7 Ultimate 64 bit
 
 

Here are the mods I made on the third HDD cage I'm adding. These are pictures of a stock cage:

Got a New Case!-img_0001.jpg

Got a New Case!-img_0002.jpg

The problem I had was the three tabs that stick out below the bottom of the case, making it harder to seal the holes where they stick through. this is a shot of the bottom of the cage with the three tabs sticking up. Take a good look at them because...

Got a New Case!-img_0007.jpg

...they just went away.

Got a New Case!-img_0010.jpg


My System SpecsSystem Spec
04 May 2014   #66
Lady Fitzgerald

Win 7 Ultimate 64 bit
 
 

This shot shows the third HDD cage installed to the left of where the front two HDD cages go. I've already lowered the front two cages by shortening the base the cages are mounted on and moved them forward so they are the same distance from the side of the case as the third cage is. Basically, I'm fixing some poor engineering design on Corsair's part.

Got a New Case!-img_0012.jpg

This shot shows the two thumb screws that secure the third HDD cage to the case. The back two corners of the cage fit into clips punched from the bottom of the case which keeps them in place. However, since I removed the tabs that secured the front two corners, the only thing holding them down is the front thumbscrew which doesn't secure the right front corner. To secure that corner, I drilled a hole in the bottom of the case inline with an existing hole in the cage and will use a screw and Nylock nut to secure it. I was hoping to keep the fasteners for the cage completely tool-free but that's the way the cookie bounces. I'm not likely to be removing that cage very often, if at all, so it's not that big a deal.

The little white arrow points at what used to be a tab that helps to align the case side panel. The case side has a V shaped trough that fits over the side flange so all the three tabs do is keep the side from moving fore or aft. Since the outside tabs can handle that job just fine without the middle tab and since the middle tab interfered with removing the bottom HDD tray from the third HDD cage, I removed the stupid thing (some Corsair engineer had her/his head up a dark, moist, and smelly place when designing that!). You can better see the nut that is securing the front bottom corner of the third HDD cage in this shot.

Got a New Case!-img_0015.jpg

This shot shows why I lowered the front two HDD cages. Originally, there was no way for air from the front fan to flow across the front HDDs to the HDDs in the third HDD cage. Now that the HDDs are on the same level, some air can get to the top two drives in the third cage (fortunately, they won't need much). The bottom drive won't get any airflow but that's where my SSD will go so no worries. (Those HDDs are two of the three dead ones I keep knocking about to use for dummy drives for making cables, etc. rather than risk messing up a good drive.)

Got a New Case!-img_0022.jpg

The horizontal arrows in this shot shows where the flanges I cut off the third HDD cage would have poked through the bottom of the case. Since they are no longer there, I can rivet some little aluminum panels (engraving tags, actually) over the holes to seal up five major air leaks. The vertical arrow points to where I drilled the hole to secure the corner of the third HDD cage.

Got a New Case!-img_0040.jpg


My System SpecsSystem Spec
04 May 2014   #67
Lady Fitzgerald

Win 7 Ultimate 64 bit
 
 

The arrow in this shot shows the gap that now exists between the 5.25" drive cage and the top HDD cage. The base the two front HDD cages are mounted to is plastic and has only two little screws biting into the plastic of the base and a couple of loosey goosey plastic flanges holding the lower cage in place so there needs to be a secure connection at the top of the top HDD cage to ensure the HDD cages are secure. I lost that support when I lowered the cages so now I get to replace it.

Got a New Case!-img_0024.jpg

The bottom of the HDD cages and the bottom of the 5.25" cage have pretty much the same connecting flanges so I cut the bottom off an extra HDD cage I bought for the purpose to restore the support I lost.

Got a New Case!-img_0031.jpg

The diagonal arrows in this next shot shows the flanges that interlock with mating flanges on the top of a HDD cage. The vertical arrows show two notches I had to cut to clear the flanges on the top of the HDD cage. The horizontal arrow shows the tab that takes a thumbscrew to lock the HDD cage in place. I had to remove that tab from the 5.25" cage because it was no longer long enough to reach the top HDD cage.

Got a New Case!-img_0032.jpg

The next shots show the cage bottom attached to the top of the top HDD cage for a trial fit. It's nice and snug, which is what I needed.

Got a New Case!-img_0036.jpg

Got a New Case!-img_0038.jpg


My System SpecsSystem Spec
04 May 2014   #68
Lady Fitzgerald

Win 7 Ultimate 64 bit
 
 

The bottom row of holes (see bottom arrow) in the plate I cut from the bottom of a HDD cage are actually a form of hollow rivet made by punching a hole forming a deep flange that is then inserted into another hole and peened. I decided to use those holes to mount the plate to the bottom of the 5.25" HDD so I drilled matching holes on the other side of the plate (see top arrow).

I had the Divil's own time trying to figure out how to transfer the holes in the plate to the bottom of the 5.25" cage. What I finally figured out was to put some blue tape on the bottom of the 5.25" cage, mount the plate to the top HDD cage and install the cage, made sure the cage was exactly where I wanted it, then draw an outline of the plate onto the tape. After removing the cage and the plate from the cage, I positioned the plate on the bottom of the 5.25" cage, using the outline I drew, then marked the holes for drilling.

Got a New Case!-img_0042.jpg

This shows the drilled holes in the bottom of the 5.25" cage. I will have to get some spacers and rivets to secure the plate to the 5.25" cage. I will have to use rivets because I don't have much room between the top of the bottom of the 5.25" cage to the bottom of any 5.25" device that gets installed above it.

Got a New Case!-img_0044.jpg


My System SpecsSystem Spec
04 May 2014   #69
Britton30
Microsoft MVP

Windows 7 Ultimate X64 SP1
 
 

That's a lot of good sheet metal engineering Jeannie.
My System SpecsSystem Spec
04 May 2014   #70
Lady Fitzgerald

Win 7 Ultimate 64 bit
 
 

Quote   Quote: Originally Posted by Britton30 View Post
That's a lot of good sheet metal engineering Jeannie.
Thanks! Daddy was a machinist and I've had some machine shop experience and training (albeit rather moldy). I've gotten a lot of my modding ideas from OCN forums. There's one forum there for cases and one thread dedicated to the 650D.

My biggest problems are being able to see what I'm doing (the old eyes aren't what they used to be) and my hands aren't all that steady anymore.
My System SpecsSystem Spec
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