Project: Beast 2.8

Stevennoland

Limp Gawd
Joined
Jan 5, 2006
Messages
418
Hello avid computer users, gamers’, and system modders and builders. I’m back with another work log.

Don’t fret, Beast III isn’t dead. I’ll actually be using some of it for this build. This build will be an update to Beast 2.75; the system I’m currently using.

Since Intel released its current speed champ, the i7 series, I knew it was time to upgrade. I had done some research and concluded the 920 proc was the way to go. An X58 mobo was also in order. And to get the best memory performance, 3 x 2GB of 1600 mem (minimum) was also on the menu.

I had a spare Lian-Li / Rocketfish case lying around, so I decided to use it as the backbone. I wanted to water cool as well. I will be using many of the parts from Beast 2.75 for most of the water cooling.

This case is certainly not as well built as some of my other Lian-Li’s, but it does have some features I like. The space at the top above the MOBO section is perfect for a triple rad set-up that is actually located inside the case (unlike Beast 2.75). I can also remove all the HDD cages since I’m planning on using an SSD for the OS and progs. I can also ditch the 3.5” cage since floppies are so out. First, some shots of the case.
IMG_5220.jpg


IMG_5223.jpg


IMG_5225.jpg


IMG_5227.jpg


First step was to add some handles (these are the same ones on the doors of the CNC lathes I use at work). These suckers are beefy, and at $20.00 each, they had better be.
RFhandle01.jpg


RFhandle02.jpg


Here is a shot of the holes for the handles
rocketfish001.jpg


Here are the filters I made for Beast III. Since this case has the space at the bottom, I chose to incorporate them into this build. I also wanted to cut down on the dust intake as much as possible.
filter001.jpg


Here are the cut-outs for the air flow. I used my Roto-Zip to rough these out.
filterinlet001.jpg


Wicked burrs!
filterinlet002.jpg


I then filed the edges smooth. Back intake.
filterinlet003.jpg

Front intake
filterinlet004.jpg


Holes for the rails to hold the filters
filterinlet005.jpg

filterinlet007.jpg


Close fit
filterinlet006.jpg

Here is the middle rail. There are two sets of holes because some idiot dimensioned in ‘Paper Space’ instead of ‘Model Space’. If you don’t know the difference, ask someone who uses Auto CAD. Shame on me.
filterrail001.jpg

filterrail002.jpg

filterrail003.jpg


Here are the end rails
filterrail006.jpg

filterrail004.jpg

filterrail005.jpg


Here is the mounting hole (the thread is in the elbow). If you want to see how these were made, check my Beast III worklog
filter002.jpg


Rail with hole to show line-up
filter003.jpg


Attached
filter004.jpg


Here is the back end rail installed
filterinlet008.jpg


Middle rail
filterinlet009.jpg

Front end rail
filterinlet010.jpg


The filters slide into position. I had intended to use four screws to hold each filter in place, but getting to all four screws once this thing is complete will be a PITA. I may only use two.
filterinlet011.jpg


Since I want the filters to actually prevent dust from getting into the case, I had to block off all other entry points. Let’s start at the bottom. These are the holes under the PSU.
PSUvent01.jpg


I squared up a piece of a remnant cut-out (actually the cutout for the top rad) to block these holes. The two holes in the center are for the PSU support.
PSUvent02.jpg


Screws, washers and nuts
PSUvent03.jpg


Installed
PSUvent04.jpg


This is a shot of the slits below the PSU. I don’t have a remedy for this yet.
PSUbackvent01.jpg


Next up are the holes for the GPU fan exhaust
GPUvent01.jpg


Covered
GPUvent02.jpg


Next up are the top vents
topvent01.jpg


Plate
topvent02.jpg


Installed
topvent03.jpg


Here is the plate to cover the 3.5” drive bays.
35vent01.jpg


Covered
35vent02.jpg


Getting the 5.25” unused bays covered will be the hardest. I will probably use some clear silicone gel to cover any remaining air entry points. A complete seal is impossible, but I’ll certainly give it a shot.

The stock rubber feet were not going to give me the proper height for the intake filters.
RFfoot001.jpg

RFfoot002.jpg


So I made these. They will also provide a wider stance to reduce side tippage
RFfoot004.jpg

RFfoot003.jpg


Screw and washer
RFfoot005.jpg


Installed
RFfoot006.jpg


In this shot you can see the difference in height. More than enough for adequate air flow.
RFfoot007.jpg


Here are some shots of the parts that will be utilized for this build. Plextor PS-850XA DVDRW
DVD01.jpg


Shiny front.
DVD02.jpg


SATA interface
DVD03.jpg


Next up is the CPU. ‘C’ stepping I believe
i792001.jpg

i792002.jpg

I was originally going to do a GTX 280 SLI set-up, but the water blocks (front and back) for two 280’s was going to run me almost $500.00. I am currently using an EVGA GTX 280 in my current system, and I purchased this BFG GTX 280 for the SLI
bfgGTX280001.jpg

bfgGTX280003.jpg


I know a pair of GTX 280’s in SLI is pretty decent and more than enough for a 24” monitor @ 1920 x 1200, but I couldn’t bring myself to drop the $$$ on the EK front and back blocks. So I decided to opt out and get a GTX 295. I know, I know, I can hear the groans now, but it is far easier to cool one card than two (tubing and set-up wise). To off-set the price, I’m planning on selling the 280’s.
Here is the GTX 295 I picked up @ Fry’s (check that price!)
bfgGTX295001.jpg


Candid shots (the covering on this card has the coolest rubber feel)
bfgGTX295002.jpg

bfgGTX295003.jpg

bfgGTX295004.jpg

bfgGTX295005.jpg

bfgGTX295006.jpg

bfgGTX295007.jpg

bfgGTX295008.jpg

bfgGTX295009.jpg

bfgGTX295010.jpg

bfgGTX295011.jpg


And to cool this beast I purchased the HeatKiller
heatkillerGPUblk001.jpg



heatkillerGPUblk002.jpg


Install goodies
heatkillerGPUblk003.jpg

heatkillerGPUblk004.jpg

heatkillerGPUblk005.jpg

heatkillerGPUblk006.jpg

heatkillerGPUblk007.jpg

heatkillerGPUblk008.jpg

heatkillerGPUblk009.jpg

heatkillerGPUblk010.jpg


I’m breaking in the 295 in my current system. I’ll have a post of the marriage of the 295 and the Heatkiller later.

Here is the MOBO. Pics speak for themselves
AsusR2E001.jpg

AsusR2E002.jpg

AsusR2E003.jpg

AsusR2E004.jpg

AsusR2E005.jpg

AsusR2E006.jpg

AsusR2E007.jpg

AsusR2E008.jpg

AsusR2E009.jpg

AsusR2E010.jpg


This shot gives you a good idea how much wider this board is (most boards end at the hole near the memory slot)
AsusR2E012.jpg

AsusR2E013.jpg

AsusR2E014.jpg

AsusR2E015.jpg

AsusR2E016.jpg

AsusR2E017.jpg


For initial testing I installed the CPU and memory
AsusR2E018.jpg



Here are the water cooling blocks for the mobo.
First, the naked nb
mobonb001.jpg


And sb
mobosb001.jpg


Next, the EK north and south bridge block with the acetal top
eknbsb001.jpg

eknbsb002.jpg

eknbsb003.jpg


Looks like a quality control issue
eknbsb004.jpg


Look at those burrs!
eknbsb005.jpg

eknbsb006.jpg

eknbsb007.jpg


Inside
eknbsb008.jpg

eknbsb009.jpg


I was able to get the paper off, but what appears to be adhesive won’t come off. It seems like it will seal though.
eknbsb010.jpg


Next up is the block for the CPU. This is the same block I used for Beast 2.5, but the aluminum plate had to be remade to fit the different sizing for the mobo holes.
CPUblk001.jpg

CPUblk002.jpg


New top plate
CPUblk003.jpg

CPUblk004.jpg

CPUblk005.jpg


Next up are the mosfet blocks.
ekmosfet01.jpg

ekmosfet02.jpg

ekmosfet03.jpg


Naked mosfets
mosfet001.jpg

mosfet002.jpg


In order to get the stock heatpipes and blocks off the mobo, you are required to remove the QPI power riser card
QPIcb01.jpg

QPIcb02.jpg


The ‘Republic of Gamers’ lighted logo
ROGlight01.jpg


Backside
ROGlight02.jpg

I wanted to reuse this logo, but I had no place to put it. There is a heatsink attached to the top of the QPI card, and this lighted logo is glued to it. But when you remove the stock heatpipes and blocks, there is nothing to attach the QPI card heatsink to. So I came up with a brilliant plan to make a water cooling block for it.

See next post.
 
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Continued from first post.

I first started by drawing the QPI card in 3D using Auto CAD, here are some JPEG shots
qpiassy01.jpg

qpiassy02.jpg



I thought it would be cool to have the block cool both sides of the card, so I came up with this idea
This image shows just the top copper cooler
qpitopcooler01.jpg


Bottom view
qpitopcooler02.jpg


Here is the bottom cooler block
qpibottomcooler01.jpg


Bottom view
qpibottomcooler02.jpg


Here is the cap for the bottom block
qpibottomcap02.jpg


Here is the top cap
qpitopcap01.jpg


Some assembly shots
qpiblockassy01.jpg


Side view
qpiblockassy02.jpg


End view
qpiblockassy03.jpg


Bottom view
qpiblockassy04.jpg


With QPI power card added
qpiblockassy05.jpg

qpiblockassy06.jpg


Here is the actual Acetal material
acetal001.jpg


Copper
copper001.jpg


Acetal squared up, bottom cap
qpiacetalbot001.jpg


I’m planning on making four of these (if all goes well, I plan on selling the other three)
qpiacetalbot002.jpg


Top acetal caps
qpiacetaltop001.jpg


The lot
qpiacetaltop002.jpg


Bottom copper
qpicopbot001.jpg


The lot
qpicopbot002.jpg


Top copper
qpicoptop001.jpg


The lot
qpicoptop002.jpg


The sandwitch
qpiinitstack01.jpg


This is as far as I have gotton on the water block for the QPI riser card.

In designing this QPI water block, I ran into some interference with the EK north and south bridge block.
After many revisions and changes, I realized that some modifications to the EK block were in order.
The two holes nearest the QPI assembly were the interference area (two holes at bottom below nb)
mobonb002.jpg


What follows is the modification to the EK nb sb blk. I needed to extend the top acetal block but below the pin block located on the mobo (where the QPI board plugs in) Here is the process. First material, 316 stainless steel (we didn’t have any plate stock, so I cut it out of a 2” round bar)
eknbsbblkext001.jpg


Sawed end
eknbsbblkext002.jpg


Next came the square up
eknbsbblkext003.jpg


Holes
eknbsbblkext004.jpg


Clearance for the bottom copper (angles also added)
eknbsbblkext005.jpg


I originally had cut a slot into the top acetal block, but it wasn’t low enough. The five mounting screws
eknbsbblkext006.jpg


Here is the extension attached (screws are a bit too long)
eknbsbblkext007.jpg

eknbsbblkext008.jpg


Here is the extension after grinding
eknbsbblkext009.jpg


Here is the top block with the shelf removed
eknbsbblkext010.jpg


Here is the top with the extension attached
eknbsbblkext011.jpg


Proper length screws
eknbsbblkext012.jpg


More views
eknbsbblkext013.jpg

eknbsbblkext014.jpg

eknbsbblkext015.jpg

eknbsbblkext016.jpg


Top view with stainless screws to affix the top to the copper bottom
eknbsbblkext017.jpg


Here is a shot of the new nb sb block set in place. Can you see what is blocked?
mobonbsb03.jpg


This shot might give it away, the hole nearest the top memory slot
mobonbsb02.jpg


I still haven’t figured this problem out yet.

Here is another little clearance problem
mobonbsb04.jpg


The lock release for the PCIe slot is blocked. Another view
mobonbsb05.jpg


I could modify the acetal top block or shave a portion of the lock release off. I haven’t decided. I can tell you I’m a little disappointed with the design. EK should be ashamed.


Here is the modification to the top of the case for the fitting of the x3 120mm rad and grill. This is a shot of an aluminum block attached to a scrap piece of plexiglass. I affixed the top of the case to this to machine the opening for the rad (actually the fans). The block is so I can grab this monster in the vise we have on the mill.
RFtoprad001.jpg


Does the plexiglass looks familiar? It’s the same piece I used for machining the B3 in the door for Beast III
RFtoprad002.jpg


Cut-out!
RFtoprad003.jpg


The x3 120mm rad and fans
RFtoprad004.jpg

RFtoprad005.jpg


Top in place
RFtoprad006.jpg


Rad in place
RFtoprad007.jpg


Close-ups
RFtoprad008.jpg

RFtoprad009.jpg


Screwed and handles added
RFtoprad010.jpg


Close fit eh?
RFhandle03.jpg


That’s all for now. I’ll have more to post a little later. I’m working on refitting the power cables for the GPU.

Stay tuned!
 
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This looks really good. I'll be keeping an eye on this badboy. ;)

By the way, that is a killer deal you got on that GTX 295! I'm jealous, lol.
 
This is incredible. What kind of equipment are you using to cut all of this?
 
amazing job so far man! beautiful in every way. you have some unbelievable skills.
 
I could modify the acetal top block or shave a portion of the lock release off. I haven’t decided. I can tell you I’m a little disappointed with the design. EK should be ashamed.

sorry to hear that your EK block didnt work out. :( i would go with trimming a bit off the block since youve already modded it. that way you can keep the warranty on your mobo. (assuming it hasnt already been voided.) otherwise i suppose the lever would be easier to fix.

damn good work here. having access to a CNC mill is so nice, but man i hate standing there for hours just squaring up the stock, let alone actually making something! :D
 
Back with more! Thanks for kudos people.
I know the DDC pumps can be mounted in any direction, but I wanted to keep them upright (if that is the correct term) with the inlet at the top. I was limited on space, so I decided to make some brackets.
First, the material. This is 6061-T6 aluminum. I have been informed it is called ‘channel’. If anyone has a more correct term, please let me know.
channel01.jpg

channel02.jpg


3 inches high
channel03.jpg


This was the smallest remnant Industrial Metal Supply had. The sales guy sold it to me for less than $18.00 . A good deal if you ask me.
channel04.jpg


Next, I cut it into rough shape on the cut-off saw. I ended up with ten blanks. If anyone wants one of these made, PM me and we can work out a deal
Lbracket001.jpg

Lbracket002.jpg


Machined to size
Lbracket003.jpg

Lbracket004.jpg


I didn’t need the angled surface, so I left it alone.
Lbracket005.jpg


Mounting holes
Lbracket006.jpg


Nice burrs eh?
Lbracket007.jpg


Next up, the window for the fitting and the mounting holes for the plexi top.
Lbracket008.jpg

Lbracket009.jpg

Lbracket010.jpg

Lbracket011.jpg


Pump attached
Lbracket012.jpg

Lbracket013.jpg


Close-ups
Lbracket014.jpg

Lbracket015.jpg


Here are the templates for the L brackets in the case
mountholetemplate01.jpg


Mounted
Lbracket016.jpg

Lbracket017.jpg

Lbracket018.jpg


I made these brackets to help even out the load.
Lbracket019.jpg



This is the solution to the covered mobo mount hole the EK nb sb block created. I figured I would incorporate the mount into the mobo and secure it with a nut. First, the stand-off
newmobostndoff01.jpg


With washer and screw
newmobostndoff02.jpg


Installed
newmobostndoff03.jpg

newmobostndoff04.jpg


Shot of normal stand-off mounting hole
newmobostndoff06.jpg


With stand-off
newmobostndoff05.jpg


Back side
newmobostndoff07.jpg


Opened up
newmobostndoff08.jpg


Mobo installed
newmobostndoff09.jpg


Secured with 4-40 nut. This was the easiest remedy. Another alternative was to drill holes in the mobo tray where the mounting screws for the nb sb block are, and secure the block after I installed the mobo.
newmobostndoff10.jpg



I got a little more done on the QPI power riser card water block. The top cap
qpiacetaltop003.jpg


With fittings
qpiacetaltop004.jpg

qpiacetaltop005.jpg


Top copper block
qpicoptop003.jpg


Bottom copper block
qpicopbot003.jpg

qpicopbot004.jpg

qpicopbot005.jpg


I got a little inpatient and broke a tap off. I’m hoping it won’t cost too much to have it burned out.
qpicopbot006.jpg



My PC Power and Cooling 1KW PSU does not come with PCIe 8 pin power connectors, so here is the remedy for that. First, a regular 6 pin connector
PCIErefit001.jpg


Here is the 8 pin adapter that came with my GTX 295 next to the 6 pin
PCIErefit002.jpg


The only thing that is different is the addition of two ground wires. This is completely stupid and is a conspiracy between GPU and PSU manufacturers to sell more PSU’s
PCIErefit003.jpg


Female PCI pins
PCIErefit004.jpg


I made this extractor a long time ago. It is a piece of banding strap ground to about .04” wide (.03” thick)
PCIErefit005.jpg


I just push it in on each side of the pin
PCIErefit006.jpg


TADA!
PCIErefit007.jpg


In this shot you can see how the wings on the pin are bent inwards allowing for housing removal
PCIErefit008.jpg


6 pins removed
PCIErefit009.jpg


Stripped
PCIErefit010.jpg


Here are the new pins with the addition of two ground wires added to the existing ground wires (I know it looks like shit, but I swear these pins are not designed for more than one 18 gage wire per)
PCIErefit011.jpg


Installed with new heat shrink and zip tie
PCIErefit012.jpg


That’s all for now.
 
Wow, there are so many detailed images on this build, it's bordering on pornographic.
 
i did the exact same thing with my power supply. it is very difficult to get 2 wires on one pin. the others are cake.
 
Damn dude, your Rocketfish is simply amazing. If I had the money...

... I couldn't do that. :(
 
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