Liquid Cooling System project v1.0

[freexbox]

My liquid cooling project v1.0.

So it all started back in the day with fish tank cooling systems and home made water blocks. I got the ich, but never took the step until now.

I had read a dozen or so tutorials on how to build everything from water blocks to cooling towers, using coke bottles, fish tanks, and toilets for reservors, making pumps from various aquarium parts, or by using a pond pump found at the local home depot. The finest materials were used aluminum, copper, acrylic and lexan, to simulate the most advance to the simplest of water blocks. Everything from home-built radiators, to built by a radiator shop, to car parts were used for the radiator, some even included a 'FULL SIZE' radiator from a car, this was definitly a project for me.

The widest array of parts and highest cost of any single (home made) project I had tried to piece together. My cousin(Nick) finally convinced me to take all the hours of reading/talking about this project and put some of it to use. After all he knew my dad had more parts in his shop than you'd see on 2 seasons of Sanford and Son. Speaking of pops I think it's time to explain, I contract to my dad in his 'Industrial Air Compressor' business, as does my cousin. So we have found a bit more 'free' time to work on our own projects or spend that time with our families.

That being said I'll get to the point. We told my dad about our evil little liquid cooling project and he was more than happy to dig through mounds of old hoses, and other oily crap, to find us 'THE PUMP' despite the mess you would see when you look at our 'shop' (2 storage buildings with shelving/tools) you would be surprised how a guy can find exactly what he's looking for. i.e. dad.

We took that little 'submergable pump' and put it to the test, running it all night in 3 gal. of water, we found that in the morning the pump and water was pretty warm so we decided to ditch the dad pump, and go with something else, as our CPU/GPU would thank us later. After many hours of research that nick did on water pumps, comparing GPH and PSI and various other factors submergable and dry. We decided to check out the local shops, we checked all the local 'fish' shops, and didn't find anything under $20 HD and Lowes didn't have anything to get excited about. So we went to Garden Ridge were we spotted a nice little $17.99 submergable 140 GPH pump.

As for a radiator I had several ideas in store, I had read several articles about using various 'heater cores' from early model chevy/fords, thanks to the guys at the local Autozone we found several nice sized units but most of them were >$30 remember this is a 'cheap' project other wise I would just buy the one's from newegg for $125. Nick had a friend at the Ford dealer who suggested a 1999 F350 Power Steering Oil Cooler which turns out to be a PERFECT size about 5" x 6" and only 3/4" thick. However it was $44 and even though Autozone can get an 'aftermarket' one for $19 they don't have it in stock. I had already picked up a little 'heater core' from Al's Radiator Shop nick had spotted it among the piles of new/old radiators in his shop. We found one that looks like the same one at Autozone from a 1991 Ford Escort, he let us have it for $10, so for the v1.0 it will be fine, when I make my pretty one for home I'll probably be getting the $19 that is smaller.

I had a little idea brewing on how to make my water block since the begining of this little project a cross drilled block that would flow water in a 'U' shape through the block for maximum cooling. Found on various liquid cooling guide across the internet. I found a 'bar' of aluminum at the shop to use for the water block and with a little cutting/drilling, and  voila a custom water block for a P4 478 chipset.

There is much more to this project, it is about half done. The water block has been built and leak tested, since then I took the water block apart to 'polish' it for a mirror finish, we still need to build a good external case. We started this project wanting to build an internal unit, and whilst our parts are small enough, we opted for an external due to dust/servicability. This way there are NO FANS in the computer when we are done.

And hence forth I bring forth the pics.

-Matt

[freexbox]

More pics, there small so shouldn't take up a bunch of BW.

-Matt

[aint skierd]

Cool!!( pun intended)

Neat project. Having been an aircraft mechanic, I have often considered such a project, just because I particularly enjoy using components designed for something else and modifying their application.
I finally decided that if i ever wanted to create a computer with the ultimate cooling abilities, I'd just use one of those 30x30 "dorm fridge units," and mount everything in there. Cool as can be, and dust free. Not too pretty, and not nearly as much fun as your project!

Be sure to record operating temps so you will know precisely how well it works.

[freexbox]

Here are some more pics, a look at the solid block that the waterblock was made from. A look at my 'GPU waterblock' in the first stages. This is our 'reservior' taped together, maybe tomorrow we will get it glued together. And also a pic of the water pump, after I threaded it for 1/4 pipe and put the hose barb in, perfect size!

-Matt

[freexbox]

Well it's been ages since I worked on my water cooling system, but here goes.

We got the GPU water block almost done, here is a picture of it below cut out with the groove cut in it for water flow we will have a 1/4" thick plexi glass 'top' on it that will be threaded for the 1/8" fittings.

Also we have pictures of our first case. Started out life as a UPS, and now onto a water cooling system, before, after pics this thing was full of junk. We took it all out, and found our v1.0 radiator would not fit, so we ordered the smaller one yesterday. Also notice my 'completed' reservior, it's way to big for this case. We will be making a new one when I get the new radiator and lay it all out.

-Matt

[aint skierd]

Man, you and I would get along great! Good use of the hands dude.

Impressive. Nice clean design / fabrication.
Nice shop too. Was that cutter in a mill or drill press?l

[freexbox]

Actually it's all my dad's 'shop' if you will for our business. Not really tools we use in the business I'm sure you know how that goes.

It's a makshift mill, a drilpress with an end mill bit and a vise that can be moved side to side and back and forth to achive the same as a mil, not quite as accurate as I would like but it free!

Should have some more progress next week, won't be finished or anything, I'm about to take a trip across the pond to western europe so it might be a while before I post again, things can get a little hairy when vacation comes around.

-Matt

[aighead]

OK, so I have to make a tasteless reference to a joke about your choice of words there Matt. Western Europe and hairy, is a funny way to put it.

[aint skierd]

OK, so I have to make a tasteless reference to a joke about your choice of words there Matt. Western Europe and hairy, is a funny way to put it.

That's funny!! Referring to the European females dislike of shaving... anything.

Yeah, Freexbox, that's how my "mill" works too!
You enjoy the vacation man.

[freexbox]

Dude that is friggin hillarious! I didn't notice that. Glad you posted I need to check your forums! Well I got the new radiator today more follows soon!

-Matt

[aighead]

HA! There is nothing going on in my forums! They are as boring as ever!

[freexbox]

Below you should see the new radiator, which will be mounted to the lid, we have the 'loop' part of the radiator going out the back of the case to allow for more room, also the marks on the lid ready to cut, just can't decide what way to cut it. Die grinder, chop saw, sawzall, or dremel.?!?

All in all the new radiator fits nice and we need some fans about 2.75" just haven't had time to convert it to CM/MM to figure out which fans are the closest. Mounted in the lid should allow for sufficient airflow, and allow a lot larger reservoir inside.

[SuperG]

Does the new radiator have turbulators in it? The problem with any water cooling system is if you get laminar flow. This is where the water assumes a constant/fixed path and the outside water cools some but the core water stays hot. Turbulators cause the water to spin and maximize surface contact and better cooling.

[aint skierd]

Heya - I would probably opt for the dremmel for a clean, distortion free cut. set up a shopvac or another source of ventilation. Those cut off discs are a silicon carbide grit, the dust is to be avoided unless the threat of silicosis doesnt scare you.

It would be ideal to roll that edge under by an eighth or so. Would give a nice soft edge.

looks like a pro job there.

[freexbox]

Dunno about the turbilators, guess we will see how it works?

-Matt