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.

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Conceptual drawing by E.E.L. Ambiense


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


Machined Aluminum Computer Case Feet Link

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Acoustical Sound Proofing Sheets for your PC

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

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

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This is the Honeycomb Modders Mesh we used.

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

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

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

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

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Adding window to Cooler master 840 ATCS
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Using tape roll to make curved corner
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Make first initial cut with your Dremel and cutting wheel, to allow use of Jigsaw and cut the window more efficiently

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You have created slot, this allows using a Jigsaw w/ 18 TPI cutting blade
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Using a Jigsaw is much quicker than using a Dremel to cut your window
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MonsterMawd

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

Cooler Master 840 ATCS rear 120mm exhaust
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I'm holding up a 140mm Cooler Master fan over the stock 120mm grill. "Will it fit without anything obstructing it?"
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The location of the 140mm fan resides along the crease on the back plate.
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Making the initial cut with Rotary tool and reinforced cutting wheel before using Jigsaw
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Using Jigsaw with 18 TPI metal cutting blade
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Using rounded side hand file to clean up burrs along the edge of the cut.
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140mm opening is cleaned up, next is drilling mounting holes for 140mm fan
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vibration dampening fan grommets
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Using a 1/4" size drill bit to make the mounting holes, this allows the fan grommets to fit.

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Vibration dampening fan grommets installed.
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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.

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

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"Look Ma, No deburring needed!"
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The benefit of using Lexan is that you can drill or hand punch it without cracking it.

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Clean hole cut! I love Lexan.

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

MonsterMawd

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Jan 31, 2006
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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

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Are you a fan of the Black Ribbon power cables?

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MonsterMawd

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The concept called for bullet holes in the window

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Using 3/8" drill bit
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Using wire cutter to make cracks around the hole
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Etching Rotary Tool (or Dremel) Engraving Bits
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Using the dremel to emulate some cracks
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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

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MonsterMawd

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1/4" thick acrylic sheets will act as reinforced segments of the side panels.
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Heres a close up of the vertical blade cutting 1/4" acrylic sheet
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These edges are not acceptable
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Black & Decker Mouse Sander with Medium grit sandpaper
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Thats better!
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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
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MonsterMawd

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Jan 31, 2006
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Thank you, you should wear safety glasses. I can't cover up the bullet holes..lol

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I used the Dremel with a cutting wheel to emulate impact to the reinforcement panel.
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Using Dremel with egraving bit to gouge the other bullet hole under the acrylic. A ventilation hole was added as well.
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Round Modders Mesh used as the ventilation grill in the left side panel.
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Scotch Weld DP-190 2 part epoxy is used to attach the Modders Mesh to the backside of the side panel
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MonsterMawd

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Jan 31, 2006
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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.

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