mac pro mod with custom shaped thin metal sheet

Discussion in 'Mac Pro Mods' started by serkanp, Nov 10, 2016.

  1. serkanp

    serkanp

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    Nov 10, 2016 at 6:10 PM #1
    serkanp

    serkanp

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    hi guys,
    i read all case mods made for mac pro, and i was thinking to buy https://www.amazon.de/dp/B000TGKBRC/?tag=tonymacx8603-21 but it is plastic..

    then i found this 3d stl model https://www.cgtrader.com/3d-print-m...cs/full-printable-itx-case-mac-pro-2013-style but it costed too much and not good enough..
    then i thought i can maybe do it with a soucepan :) or i can create from scratch..
    after googling, found that they are made with metal spinning and custom shaping.. :)
    i found a local expert and asked him if he can do it or not.. he said yes.. :)
    ok here are the first prototype pictures..
    started choosing 3 mm thin metal plate..
    [​IMG]

    calculating size :) height 28cm, width 20 cm


    [​IMG]



    [​IMG]
    shaping..
    [​IMG]
    [​IMG] [​IMG] [​IMG]

    we need smoothing the edges..

    [​IMG]
    weneed smooth edges :)
    [​IMG]
    first part of smoothing
    [​IMG]
    more smoothing and hole on top..
    [​IMG]
    larger hole...
    [​IMG]

    lets look inside..
    [​IMG]

    cleaning..
    [​IMG] [​IMG] [​IMG] [​IMG]

    size comparing

    [​IMG] [​IMG]

    bottom:
    [​IMG]

    [​IMG]

    the first problem was, the cylinder mold was 20 cm width thats ok, but the smooth curve edge mold was 18 cm width (the local craftsman dont have 20 cm ), so curve is not much smooth..

    how much? 15 usd.. :) very cheap..

    whats next?
    - laser logo engraving..
    - choosing painting method and color..
    - choosing right motherboard lga 1155 (i have i7 cpu, rams, hd , graphics card etc.. but current motherboard is standart atx.. )
    i need help on choosing motherboard..
    - preparing panels,structure etc for holding motherboard, hard disk etc..
    - cutting usb, ethernet etc hole..

    remember, this is just first prototype case.. after preparing board, etc.. i will see minor problems and then re-create a new case..

    what do you think? :)
     
    Last edited: Nov 10, 2016
  2. YulBrinner90

    YulBrinner90

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    Nov 10, 2016 at 9:37 PM #2
    YulBrinner90

    YulBrinner90

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    Man... It's fantastic, congratulation! It can be a great thermic dissipator! Can I know how much did you spent? I'm thinking to use a fire extinguisher.

    For the motherboard... I suggest you a Gigabyte GA-H170M-Wifi!

    I'm honest... This can be the best project of the forum. Good lucky!!! :)
     
    Last edited: Nov 11, 2016
  3. serkanp

    serkanp

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    Nov 11, 2016 at 7:38 AM #3
    serkanp

    serkanp

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    its hard to do it with fire extinguisher.. you have to cut it(it has a very strong metal), you have to find exact width etc..
    metal spinning is the best and cheapest solution :)
    i thought it must be very difficult to find metal spinning workshops around in istanbul..
    then i just googled and saw that there are hundreds of places that makes custom things..
    total cost of the case is 15 usd , total work time spend was 1 hour.. all cost 15 usd .
    check these videos about metal spinning, its very interesting:



    i saw that making 28cm height x 20 cm width is too much.. i checked the dunecase's dimensions and they were using that dimensions.. i think 24 x 18 would be enough when i put the sfx power supply..

    this week i will prepare the internal hardware of the case, depending on it, i will make a better case..
    the local metal spinning place did not have 20 cm curving mold, they had 18 cm width.. so the top curve is not smooth as i wanted..
    for the bottom part, again i will use metal spinning method.. but the result item will have the air holes (laser cut)
    when i will finish it it will look like this:

    [​IMG]

    i will prepare laser cut , engraving, painting.. etc.. and i will share the results as soon as possible..
     
    Last edited: Nov 11, 2016
  4. Mac-Mike

    Mac-Mike

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    Dec 20, 2016 at 7:36 PM #4
    Mac-Mike

    Mac-Mike

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    Wow, keep us posted. I was going to make my mac pro mod a different way, but after seeing this I am rethinking my direction. Can't wait to see the finished product especially how you construct the internals and ports. Awesome idea!
     
  5. serkanp

    serkanp

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    Dec 20, 2016 at 8:32 PM #5
    serkanp

    serkanp

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    then let me update you :))
    after searching for better design, i realized that i have to build a mold for best results.
    i found a crazy man who is master on spinning metal builds. he is building trashs, pots, industrial lamps etc..
    i found him on internet with coincidence :) i was looking spinning metal workshop nearby me while driving car from google maps.
    maps said 3.4km away there is a place :) i called him and told my idea.. he called me and wanted to see the previos build.
    i show him original pictures and what i had, he loved the idea and together we build a pre-mold from an existing mold he have.
    this time we have 20cm heigh and 18.5cm width.
    the bottom part is same as much as the original dunecase's bottom design.

    we created 2 new builds.

    here are the pictures :)
    1-case build 2, before cutting top:
    [​IMG]


    after cutting top:
    [​IMG]

    2 sample, 2 different hole attemps, which one is better? :)
    [​IMG]

    interior skeleton build:
    [​IMG]


    interior tests :)
    [​IMG]

    [​IMG]

    [​IMG]

    whats next?
    1- laser cut hole for usb ethernet etc part. and for power cable and for power button.(i have to find 5-axis laser cutting workshop for that)
    2- laser cut or punch for air ventilation for the bottom part.
    3- 3d print for this hole to exact fit there.
    4- perfect painting..

    by the way, i had asrock h81m-ITX mainboard https://www.amazon.com/dp/B00EOBXQW0/?tag=tonymacx86com-20 :) luckly , Sierra runs out of the box using UniBeast method https://www.tonymacx86.com/threads/...ierra-on-any-supported-intel-based-pc.200564/.(el capitan needs some kext hacks. use this guide: https://www.hackintosh-forum.de/ind...sRock-H87M-Itx-Asrock-H81M-ITX-El-Capitan-99/)
    I used MultiBeast for post install.. just selected usb3 fix , ethernet as atheros, audio alc892 thats all.. it runs now perfectly..

    the only problem i had was booting from hard drive.
    i modified the uefi boot list using an ubuntu linux livecd. just added 1 more line to boot list. now it boots without any problem.
    here are the links for that https://www.tonymacx86.com/threads/guide-asrock-uefi-boot-fix.174726/ and https://www.hackintosh-forum.de/index.php/Thread/27737-Probleme-mit-Hackintosh-Wie-kriege-ich-El-Cap-auf-meine-Kiste-Anfänger/?postID=245228#post245228 (its german, you have to google translate)

    this is the bottom fan i used, its really very quite..
    fan: https://www.amazon.com/dp/B00JRTMCG0/?tag=tonymacx86com-20

    power supply: https://www.amazon.com/HIGH-POWER-Compact-Certified-HPF-350BR-F08S/dp/B00N1QKOR4/

    cpu cooler: https://www.amazon.com/Akasa-Ultra-Profile-Intel-Cooler/dp/B00D5T1QTC/

    cpu: https://www.amazon.com/Intel-Core-i5-4460-1150-BX80646I54460/dp/B00JIJUBAS/

    power switch: https://www.amazon.com/Latching-Button-Switch-Aluminum-Waterproof/dp/B018TK5MXC/

    ssd: https://www.amazon.com/SanDisk-Ultra-2-5-Inch-Height-SDSSDHII-480G-G25/dp/B00M8ABFX6/
    (on the pictures you see regular 2.5'' disk. i replaced it with ssd)

    bluetooth: https://www.amazon.com/dp/B006WAIVY4/?tag=tonymacx86com-20

    raiser card: https://www.amazon.com/dp/B008BZBFTG/?tag=tonymacx86com-20

    gfx not yet selected, but build-in hd4600 is ok for now..

    ram 16 gb :)
     
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    Last edited: Dec 20, 2016
  6. Mac-Mike

    Mac-Mike

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    Dec 26, 2016 at 4:36 PM #6
    Mac-Mike

    Mac-Mike

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    Thank you very much. I can't tell which one I like more. I think I prefer the case with the smaller hole. I have an appointment with a metal spinner near me on Jan 3rd. Can you post a couple of photos of the bottom case/plate? I want to get a sense of the depth and curve of it before I meet with him. I really like the brushed aluminum. I think I will do two one in brushed aluminum and the other polished black like the mac pro.

    Awesome work!
     
  7. serkanp

    serkanp

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    Dec 26, 2016 at 5:26 PM #7
    serkanp

    serkanp

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    here is the bottom picture:
    [​IMG]


    but let me give you some advices:
    i made it wrong , now its impossible to cut the air ventilation holes when its spinned.
    first cut the ventilation holes on a metal sheet.
    then put one other original sheet sticked to cutted one . cutted one will be inside.
    then put them together on the spin. with this , its possible to make metal spinning with already cutted air holes.
    also for the interior part , i changed metal construction with plexiglass. i used one 18x18 plexi and mounted the mainboard to it. and put the power supply to the other side with double sided duck tape..
    for the painting, best result will be with anodic oxidation (its called eloksal in my language :) ,or anodizing)
    but the polishing must be perfect before painting. because anodising is 0.3 micron .
    you can get this kind of results:
    [​IMG]
    next week i will share pictures after anodizing..
     
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  8. Vampnight

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    Jan 30, 2017 at 2:42 AM #8
    Vampnight

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    Hi,

    congrats to the mod, it really looks great! :)
    have you managed to finish it completely?
     
  9. Pineapple68

    Pineapple68

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    Feb 9, 2017 at 8:29 PM #9
    Pineapple68

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    Very good idea, congrats, use the sam material and the same production process in artisan way...
    Looking at the production video from Apple, it seem a child play :-/

    The expert in the field could be a carpenter with a lathe for extrusion?

    The bottom plate will be 3d printed?
     
  10. serkanp

    serkanp

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    Mar 2, 2017 at 7:24 AM #10
    serkanp

    serkanp

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    no the bottom will be still aluminium.
    here are some updates about the mod:

    upper air panel :
    [​IMG]

    upper air panel mounted:
    [​IMG]

    it is a plexiglass part, i found a local "license plate holder designer" that have laser cutting for plexiglass
    actually they are making this kind of things:
    [​IMG]

    i draw the panel in adobe illustrator and took it them.
    they cut it in less then 5 minutes:


    now the bottom part:


    bottom part laser cut finished:
    [​IMG]


    front usb panel original:
    [​IMG]

    first i previewed it with cardboard :))
    i put the panel on a cardboard, and drawed the holes, the i cut it..
    [​IMG]
    [​IMG]
    then i scanned the original panel

    again used adobe illustrator for design,just put the scanned image in a layer and drawed in vector over it.
    then plexiglass laser cut:
    [​IMG]

    [​IMG]

    next... painting..
    i still don't have time for this.. but i will do it..
     
    Last edited: Mar 2, 2017

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