Cooler Master HAF 922 project

[MonsterMawd]

My canvas for this project is the Cooler Master HAF 922

I'm using paper to make a template for 2x 120mm front intake plate.

Tracking template onto 1/8" thick aluminum sheet.

I used a Jigsaw with 18 TPI metal cutting blade to cut the design. I will refine and finish the cuts with a hand file later.

The 1/8" thick aluminum won't fit in my bending brake, so I used my bench vise to bend the aluminum.

I'm using a Mouse sander with medium Grit sandpaper to remove all of the blemishes and scratching in the surface of the aluminum

Aluminum plate surface is finished. Next step is fastening it on with pop rivets, more on this soon!

I've attached the new bezel plate on with pop rivets.

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

Overkill "Nautilus" 120mm fan grills, http://www.mnpctech.com/120mm_Overkill_Fan_Grills.html

In order to use the Knock-out punch, you need to drill a 2" pilot hole.

Greenlee Knock out Punches
Greenlee part # 730EBB-120 Last time I inquired, they were around $450 in the states + Large 3/4" socket wrench, and 2" socket. I wouldn't use anything less than 19" long socket wrench. Estimated purchase price of $550 new.

 

[JohnnyLucky]

Very nice

For simple blow holes I use a 4.5 inch hole saw with an auger that I purchased at Ace hardware. Nothing fancy but it works.

 

[MonsterMawd]

Thank you Johnny. I use hole saws as well. The advantage with KO is that it measures exactly 120mm and there is no need to debur the edges

Heres the customized bezel with the overkill grills installed

 

[MonsterMawd]

I can't escape from the idea of this case in a dark Grey Steel metallic, so Brad mixes Black with Silver metallic until I decided on this.

 

[JohnnyLucky]

The Gray metallic is good. Looks like it's either high gloss or has a clear coat. Fingerprints and smudges?

 

[tkgclimb]

Looks nice, I just started my first case mod, somewhat off your inspiring stuff.

Once I'm done I don't know what I'm going to do though, part of me wants to sell it and buy a refurbished case for cheep and mod it up again, and part of me says keep it you worked so hard.

Maybe I'll buy another cheep case and mod it and give it away/ sell it (just really to cover cost of materials)

PS: whats design/theme of this mod

 

[MonsterMawd]

The theme was up in air, but my friends at Stompfest LAN event asked if I would make a case for them.

I would keep your modded case if I were you and admire it

 

[tkgclimb]

The theme was up in air, but my friends at Stompfest LAN event asked if I would make a case for them.

I would keep your modded case if I were you and admire it

Legit, no constratins only your ideas, and I have no doubt it will turn out awesome.

 

[blackhawk1928]

Is this going to be another mod like the panzer box except a different theme, case, design...etc?
-well in that case keep up the good work and post lots of pictures, your mods are amazing.

 

[MonsterMawd]

@ tkgclimb, Thank you!

@ blackhawk1928, Yes, similar in ways, but just the case this time


fyi the paint is a combo PPG "KIA" Bright Platinum Metallic" automotive paint, with Black mixed in...

 

[MonsterMawd]

I had spare time to prep the chassis for the primer coat last night. I'm using a Red Scotchbrite pad to scuff the surface.

If you're planning to paint your chassis, you may wish to remove the pop-rivets and re-install new ones. We use 1/4" length, 1/8" diameter, Gripe range .092" - .125"

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

 

[MonsterMawd]

I'll be installing 3 of these aluminum 120mm Turbine Fans These are 2000 rpm, 79.4 cfm @ 30 dBA

 

[blackhawk1928]

^Those look like some serious fans.

 

[MonsterMawd]

Yes, and they fit the theme nicely

 

[blackhawk1928]

After you finish this, you need to do a HAF932 Mod, so i can copy it onto mine and pay you money incase you patent it lol.

 

[MonsterMawd]

hehe, that could happen, I need to get several other projects done first 😀

 

[MonsterMawd]

Better open up the rear exhaust for improved airflow as well before the chassis gets painted.

Rear exhaust grill on the HAF 922 chassis

Low tack masking tape (Scotch brand Painter's tape)

120mm Nautilus Fan grill
http://www.mnpctech.com/120mm_Overkill_Fan_Grills.html

Trace the inner opening of the 120mm Overkill Nautilus fan grill

Using Jigsaw with 18 TPI metal cutting blade.

 

[MonsterMawd]

Lets turn things upside down on the HAF.

http://www.mnpctech.com/140mm_fan_grills.html

The bottom of the HAF gets modified with this 140mm billet grill.

The slotted insert is removable, which makes tracing the inside easy.

 

[shovenose]

WOW!!!!! gr8!!!!!!!!!!those fans are. SICKOOOO lol are they expensive???

 

[MonsterMawd]

Here is the link again, http://www.mnpctech.com/140mm_fan_grills.html

Yes, very expensive for a fan grill, but they're really nice.

I'll be installing the machined Diamond Knurl case feet after the chassis is finished. The HAF 922's PSU location is on the bottom, so you've only get 3/16" space for the fastener nut. I trimmed down 2 of the included 8/32 machine screws, to use these feet in the 922.

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

7/64 size drill bit for 8/32 size machined screws included with case feet.

marking off portion of 8/32 screw to cut. I use hack saw with metal cutting blade.

 

[MonsterMawd]

We made a stencil using the SF from the Stompfest event logo. It created a weird pattern, I call it Alien camouflage ..heh

 

[MonsterMawd]

Assembly started with the HD cages, I/O covers, custom feet and 140mm fan

Dusted the tops of the feet from 20" away with Black Self-etching primer...

 

[MonsterMawd]

I really liked the speckled paint effect on the feet, so I'm repeating it on the rear 120mm Nautilus rear fan grill, http://www.mnpctech.com/120mm_Overkill_Fan_Grills.html

I masked off the face of the Nautilus grill, then painted the inner walls of the openings with Black self etching primer. flipped it over, and painted the backside as well.

I then removed the masking tape and held the can roughly 16" away from the grill and sprayed the perimeter of it. This is how you achieve the speckled paint effect.

 

[blackhawk1928]

Oh YEAH! This is going to look amazing.

 

[MonsterMawd]

Thanks for the comments! Here is the XIGMATEK XLF-F1254 120mm White LED Case Fans. These are rated 1500 RPM @ 61 CFM. Noise level is 20 dbA