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Old 04-25-2010, 11:34 PM   #11 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

Next up were the two internal mounting plates for triple 140mm case fans.




Another aluminum part requires another router template/jig. A 140mm fan was sacrificed for use as a router template:




3/4-inch aluminum flat bar was epoxied to the fan frame to keep it nice and square.



The fan housing was used as a guide to route out yet another full size jig. The jig was placed over a double layer of .10-inch aluminum sheet and routed out with a 1/2-inch flush/pattern router bit.




The finished cuts require zero cleanup (filing/sanding).

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Old 04-26-2010, 03:08 AM   #12 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

starting to take shape...nice
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Old 05-01-2010, 12:53 AM   #13 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

This is going to be sexy!
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Old 05-13-2010, 11:34 PM   #14 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

Next up are the bottom mounting plates.




Which requires fab'ing yet another router jig.

G]




The finished result:

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Old 05-14-2010, 01:05 AM   #15 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

holey crap dude! thats crazy!
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Old 05-14-2010, 01:37 AM   #16 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

Looks amazing! once again, I'm jealous
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Old 05-15-2010, 09:48 PM   #17 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

Now that I know how wide the widest plate is, the PSU mounting plate was cut to width and mounting holes were drilled.




I'm really proud of how well this turned out.



Another plate requires yet another router jig.






Both plates were routed out of one big sheet because the big sheet is easier to clamp to the workbench.








A test fit:

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Old 05-15-2010, 09:57 PM   #18 (permalink)
 
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Default Re: Project: EVGA Classified SR-2 Case

Can't wait to see the final product. Keep up the awesome work
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Old 05-19-2010, 11:43 PM   #19 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

Filed, sanded, scratched and test assembled the 5.25-inch drive rails to the PSUs mounting plate.



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Old 05-27-2010, 08:52 PM   #20 (permalink)
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Default Re: Project: EVGA Classified SR-2 Case

Next up are the 5.25-inch drive rails for the four bottom mounting plates.




These (unfortunately) required a ridiculous amount of time to complete.







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