[edit: i will start working on a major update of this pc when my exams end the 23th of june.]
Here you can see the finished project. I started this with no experience in neither woodworking or computers so my techniques used are very basic. However, i'm very pleased with the end result and i recommend anyone who is in doubt about starting a similar project to just commit to it. It's easier than it looks.
Metal/ wood file
small metal saw
chisel and hammer
cheapest jigsaw available (20 euro)
Rented a sheet metal nibbler for one day
Parts of the pc for those who are interested
MSI gtx 960
Crucial Ballistix Sport – DDR3 1600Mhz – 8GB
Silverstone SFX 450W
4x 140mm noctua fans
250GB Samsung EVO ssd
1tb WD (blue)
NZXT hue rgb controller
NZXT sentry mix 2 fan controller
LEDs didn't turn out as expected
I actually never turn on the LEDs because i very much dislike how the individual LEDs look. Only reason why i would turn them on is to show the inside.
Where it started
Last summer i worked in a carpentry for a few weeks. I saw how they used several plywood sheets stacked on top of eachother, with the inside cut out, to make small boxes. I liked the way it looked and asked if they could make me a larger one (420x420mm).
A few weeks later one of the guys dropped this piece of at my house and my project started.
Cutouts for sidepanels
First thing i did was making the cutouts for the sidepanels. The sidepanels are 390x390x5mm so i had to remove 5mm in depth and 1.5cm in hight.
I used a chisel and hammer to remove the majority of the wood.
I further refined the edges with my dremel i got for my birthday.
Installing the fans
The fans i used are 4 noctua 140×140.
I also have a different fanplacement than you would find in most standard computers. I went with 2 on the bottom and 2 on the top where the air gets sucked in at the bottom and expelled at the top. This way the hot air can follow it's natural pathway of going straight up.
Then I drilled 4 holes in the corners and used a 20 euro jigsaw with a bent blade to connect the holes.
shaping with a woodfile.
I used this method every time i had to make a hole. I wont repeat the method everytime but i will just refer to this photo with: (cfr. fanholes)
I finally used a metalfile to smoothen the inside of the square holes, taking only fractions of wood of every time until the fans fitted perfectly. They are held in place by friction only, no other screws or glue.
Here is how it looked after i also finished the bottom fans.
Installing the bays
Installing the RGB controller and the fan controller.
Cut the bay that was way to big with my dremel and smoothened the backside by rubbing it against some 200 grit sandpaper.
Looked pretty good. Again, held in place only by friction.
I went to buy my aluminium sidepanels at a local metalshop.
The fake wall is 360x360x3mm
The outer wall is 390x390x5mm
(the two smaller sheets were never used in this project)
I filed the corners with a metal file bit by bit until they fitted nicely in the frame.
Fitted the outer wall the same way.
Widened the holes to make the screwheads sit flush with the aluminium sidepanel
Installing the PSU
Fitting the PSU and deciding how to place it. (I had no plans going into this project and just decided everything on the go)
The PSU i used was a SFX psu, so it came with a metal adapter to make it fit into cases with a normal PSU hole. I trimmed it down and drilled some extra holes so i could use this to attach my psu to the back of the case.
I decided to go with black plexiglas because i like the contrast it gave next to the lighter wood.
Dimensions are 390x390x5mm (like the aluminium outer wall)
Identical to the aluminium outer wall i used a metal file to rounden the corners to a perfect fit.
Making sure there are no abnormalities in the frame.
Attaching the fake wall to the case
Just used simple L irons that i cut down to proper size using a ironsaw.
attaching them to the frame using bolts and screws and washers.
Installing the ON/OFF switch.
Bought the first circular drilling head i could find. After i drilled the hole I used a rounded metalfile to enlargen the hole a bit more.
Installig the i/o panel
I dont even want to know how much time i've spent filing all these holes with a metalfile.
Bought some stand-offs on ebay for 1-2 euro including shipping. I carefully measured and drilled the holes in the fake wall, using my motherboard as a template.
Making feet from scrapwood
I initially intended to make the feet out of aluminium but decided to go with wood anyways because it gives the case a better coherence.
I took some scrapwood and just cut out somewhat identical blocks with a metalsaw.
Cut them further to shape and sanded them smooth using 200 grit sandpaper.
Final assembly of all the components
First time turning the pc on
After 2 hours of trying to connect to ON/OF switch to the right pins on the motherboard i got my pc to turn on for the first time.
The fake wall makes sure the pc is tidy on the inside.