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LordAlfa
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Xeon Cooling, Monster Car Garage LordAlfa Oct 14th, 08, 09:58 PM #1 (permalink)
With so many bling bling setups, I am trying a new route using industrial components. In fact, 2 setups, 1. Water. 2. Air

Both setups will use a defunct Hitachi Dual Xeon pedestal server chassis. Pictures will follow. Quite identical to the Intel SC5200 pedestal server. The depth is good. This guy mounts his radiator inside.


I'll start will both mods on the chassis first and decide which to go first. I am firm on what is needed for the water setup though.

Outline:

General.

1. Convert both chassis power supplies(450W, Delta) from dual redundant to single ATX standard, Seasonic.

2. Cut the cover for window.

3. Convert 6 SCSI hot swap bay to 6 SATA hot swap bay using Intel AXX6SATADB cage.

4. Lighting will be only in white LED.

5. For the water cooled setup, the 120mm fans will be replaced with low speed units.

Water setup.
1. Motherboard is Asus DSGC-DW with dual Quad Core Xeons.

2. So far only Apogee GT or EKWaterblock is compatible with Xeons.

3. Plan to water cool the 8GB of FBDIMMs as well together will all heatsinked parts with water blocks.

4. Teflon steel braided hoses only for that industrial look. And banjo joints will be used for right angles.


5. Reservoir will be a oil catch tank styled from turbo car with level indicator.


6. A large car radiator will be used and mounted on the non windowed side. This is will not be using forced air cooling for the radiator. Need a 1m width radiator. Water will be cross flowed. Enter from the bottom on one end and up the other end.

7. Only transparent item will be flow indicators, entry into the radiator and exit from the pump.

8. Water will flow to the components from a large distribution pipe. This ensures that all the components should get first hand cooled water from the radiator than pre-warmed water from other components.
 
Jiangxue
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Jiangxue Oct 14th, 08, 10:01 PM #2 (permalink)
nice! I like the industrial look... will be eagerly waiting for more pics!
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GegeV2 Oct 14th, 08, 10:15 PM #3 (permalink)
hmm...i'm interested in ur white LED lighting...how will it look like
 
Philip
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Philip Oct 14th, 08, 10:44 PM #4 (permalink)
That's a HUGE casing!

Phil

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LordAlfa
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LordAlfa Oct 14th, 08, 10:58 PM #5 (permalink)
It is deep but short. I would like it taller but I think they kept it at 19" so that it can convert to a rack mount.

BTW, this is a 5RU case. The original board used only 3x 120mmx38mm fans at 0.85A, 2 in the middle after the drives and 1 behind. Will retain those but lower speeds to maintain total component cooling.

I think for the air cooled, I can use the Thermalright Ultra 120 Extreme without problems in closing. I can't close my 4RU case with that cooler. Most like custom the ducting.
 
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Nashaz Oct 15th, 08, 03:49 PM #7 (permalink)
interesting theme bro.. looking forward to it...

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heartykid
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heartykid Oct 15th, 08, 08:38 PM #8 (permalink)
the rad. cross flow. looking forward to some tests on that. maybe can even try double pipe heat exchanger! lol
eQ.™
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bianco
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bianco Oct 16th, 08, 03:50 AM #9 (permalink)
interesting concept.
looking forward to the completion
 
LordAlfa
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LordAlfa Oct 16th, 08, 05:13 PM #10 (permalink)
These are the raw material pictures and Monster Car Garage hacking and cutting.

This is a size comparison of the server case with an IBM MATX case.



This is how the front looks like. The front switches, LED, Drives are all removed. The panel at the bottom is the 6 HDD cage.


This is the side view of the case inside. This is meant for server class boards. Well, a server class board will be in this case but it will be water cooled.


This case is mostly riveted together. So it is drilling time!
 
LordAlfa
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LordAlfa Oct 16th, 08, 05:21 PM #11 (permalink)
The case now separated into major pieces.


This is the original PSU enclosure with the centre separating plate for the dual redundant PSU.


Interestingly, the centre plate can be shifted to the right. There are exactly the same notches to slide in.


Let's take a bet. We slide in a standard ATX PSU and Viola!


Great! Now I need to make a custom cover plate for the ATX PSU and run the Inlet/Outlet water pipes through the gap on the right. I will need to cut a hole below the enclosure for the air to be excavated into the PSU. Or, I can flip the PSU if the fan facing up. That should save on the cutting.
 
LordAlfa
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LordAlfa Oct 16th, 08, 05:40 PM #12 (permalink)
Bad news!

The motherboard tray is spot welded to the chassis cover!! damned!
See the little dimple. That is the micro spot weld.


I can remove the tray by drilling this dimple. But it will leave unsightly holes on the outside.

Solution. To dress the holes up and mount the motherboard tray with polished dome nuts(outside) and bolt.


However the devil in me is suggesting that I use spike nuts.


Let's see how it goes. Spiked or domed?
 
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Kozato Oct 16th, 08, 08:16 PM #13 (permalink)
Nice spike nuts. Where can you get them? I would say go for the spike nuts for the unique style.

Project BlackSquare
 
LordAlfa
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LordAlfa Oct 17th, 08, 09:47 AM #14 (permalink)
Thought of spike nuts and change my theme to Ghostrider. Maybe weld a chain around the chassis. Use the picture below as chassis paint. Arts student willing to do this for a small sum.




Just got the quote for the custom copper radiator measuring 800mm x 450mm x 3 row with custom end tanks included in the dimensions at $320. Shop location at Sin Ming Industrial Estate. The make huge radiators for generators, cars and trucks.
 
Last edited by LordAlfa; Oct 17th, 08 at 10:14 AM..
Pissing Intel
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Pissing Intel Oct 17th, 08, 11:33 AM #15 (permalink)
OMG! That's huge case ... nice project bro! eager to see more!
 
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