Cooler Master 840 ATCS Project

MonsterMawd

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I've started the build for Cooler Master's media suite at 2010 CES. The D-9 concept was mine after seeing the movie.

I should know by first week of November what hardware CM will be sending me.




Conceptual drawing by E.E.L. Ambiense


Case Mods & Supplies used in this project by Mnpctech.com


Machined Aluminum Computer Case Feet Link



Acoustical Sound Proofing Sheets for your PC



Mnpctech is now stocking clear and colored sheets of cast acrylic for window mods

http://www.mnpctech.com/colored_acrylic_sheet_casemod_window.html



This is the Honeycomb Modders Mesh we used.





PC Cable management clamps
http://www.mnpctech.com/CableClamp.html



http://www.mnpctech.com/Computer_Billet_Fan_Grills.html



http://www.mnpctech.com/Computer_Fan_Grills_Laser_PC_Fan_Grills.html



The canvas for this PC build is the Cooler Master 840 ATCS



Adding window to Cooler master 840 ATCS


Using tape roll to make curved corner


Make first initial cut with your Dremel and cutting wheel, to allow use of Jigsaw and cut the window more efficiently



You have created slot, this allows using a Jigsaw w/ 18 TPI cutting blade





Using a Jigsaw is much quicker than using a Dremel to cut your window
 

MonsterMawd

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Upgrading the 840's stock 120mm exhaust fan to 140mm fan.

Cooler Master 840 ATCS rear 120mm exhaust


I'm holding up a 140mm Cooler Master fan over the stock 120mm grill. "Will it fit without anything obstructing it?"


The location of the 140mm fan resides along the crease on the back plate.


Making the initial cut with Rotary tool and reinforced cutting wheel before using Jigsaw


Using Jigsaw with 18 TPI metal cutting blade


Using rounded side hand file to clean up burrs along the edge of the cut.


140mm opening is cleaned up, next is drilling mounting holes for 140mm fan


vibration dampening fan grommets


Using a 1/4" size drill bit to make the mounting holes, this allows the fan grommets to fit.



Vibration dampening fan grommets installed.
 

MonsterMawd

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I've cut the window from Lexan. It's tougher than plexiglass/acrylic, but 2 or 3 times more expensive. It won't shatter or crack "easily" You can buy Lexan sheets at Home Depot, Lowes and some hardware stores like Ace.

The window will be fastened with 1/4" socket head screws, for reinforced armour look

Using center punch to mark each fastener hole.



Roper Whitney No. 5 Jr Hand Punch kit available here
Hand punch (estimate $60 new)





"Look Ma, No deburring needed!"


The benefit of using Lexan is that you can drill or hand punch it without cracking it.



Clean hole cut! I love Lexan.





Ironically our concept drawing calls for bullet holes in the Lexan "bullet proof" window...lol
 

MonsterMawd

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Cooler Master's hardware list for their CES show display

1 x Intel Core 2 Duo E8500 Wolfdale 3.16GHz 6MB L2 Cache LGA 775 65W Dual-Core Processor
1 x Intel Extreme Series DX48BT2 X48 Motherboard
1 x Silent Pro RS-600-AMBA-D3
1 x CM MITX Cooler 38mm tall (will be replaced with future V series cooler)
1 x Sapphire ATI Radeon 4870 512MB
1 x 4GB DDR3 Kingston 1600mhz memory kit
1 x WD 500GB HDD
1 x DVD drive

Silent Pro RS-600 Watt-AMBA-D3 PSU
http://www.newegg.com/Product/Product.aspx?Item=N82E16817171036







Are you a fan of the Black Ribbon power cables?

 

MonsterMawd

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The concept called for bullet holes in the window



Using 3/8" drill bit




Using wire cutter to make cracks around the hole


Etching Rotary Tool (or Dremel) Engraving Bits


Using the dremel to emulate some cracks
 

MonsterMawd

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I'm adding bullet holes to the case too, so I drilled holes in the 840's aluminum panel. I then used a tin snip and needle nose plier to cut and rip the 3/8" hole open





 

MonsterMawd

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CM is planning to show their new V-series cooler, they wouldn't reveal the model to me. I may rig a Cat Food can as cpu cooler, just for joke when they open the case....lol Cooler Master only sent 1 hard drive, so no sense in keeping the HD bay!

Use 1/8" drill bit to remove HD bay



 

MonsterMawd

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1/4" thick acrylic sheets will act as reinforced segments of the side panels.


Heres a close up of the vertical blade cutting 1/4" acrylic sheet


These edges are not acceptable


Black & Decker Mouse Sander with Medium grit sandpaper


Thats better!


Starting on other side tonight, this side still needs exploded hole, and I need to get more 1/4" socket head screws. Those will be countersunk

 

MonsterMawd

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Thank you, you should wear safety glasses. I can't cover up the bullet holes..lol





I used the Dremel with a cutting wheel to emulate impact to the reinforcement panel.


Using Dremel with egraving bit to gouge the other bullet hole under the acrylic. A ventilation hole was added as well.


Round Modders Mesh used as the ventilation grill in the left side panel.


Scotch Weld DP-190 2 part epoxy is used to attach the Modders Mesh to the backside of the side panel
 

MonsterMawd

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Here is some screen shots taken from the movie trailer on Youtube. I think it's important to have the prawn canister implemented into the case. If Cooler Master had requested watercooling, it would been fun to make a reservoir based on the canister, but the system will be air cooled. We have some 2" diameter solid rod on hand we could use to re-create something close to it. I have some ideas, but want to have it my hands first before I commit to them.





 

MonsterMawd

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Started on the paint last night, White and Orange segments





The "Pumpkin" Orange color was done first. The perimeter of the " exploded hole" will be airbrushed with a burned surface effect
 

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