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Unfortunately I did not get pictures of the chassis as I found it at a metal scrap yard. It started life as a rack for some medical equipment and was about 5 feet tall. After i got my hands on it and cleaned it up, I cut it down to 20 inches tall. It had a drop in top and sides which I scrapped to replace with acrylic panels.

  • Depth: 32"
  • Height: 28"
  • Width: 23"

The housing mounted in the bottom is what makes Project HeavyBlue special, more on that later.

This is the case for the computer that HeavyBlue houses, it mounts to the gray sliding rails in the previous picture.

A cramped computer case can get extremely annoying when your working inside it, so since I'm in charge - easy access all the way. This case mounts on the gray sliding rails in the previous picture, this particular case is 4U and 22" in depth. I told you it was easy access.

I wasn't lying, now to provide for the mess of cables and hoses that are going to be coming off the back of this computer case.

Which is why there's the funny looking bent thing hanging off the back of the case.

Viola! A folding cable guide. If you ever want to use one of these, good luck finding one anymore. FYI some sheet stock, angle stock, and door hinges make a pretty good substitute.

Here is a shot of the coolant reservoir, I welded it together from 1/4" Lexan.

How do you weld plastic? Either you have a plastic welder, or a good hot air gun with a tight nozzle works just as well and for much lower cost.

Advantage of welding the acrylic rather than gluing with the special agents or silicone, this will never split. Just like with metal welding, the bead you lay down is much thicker than the materials you are joining.

Here I have installed the water pump and the AC distribution block.

About the pump, yes it really was a beast. At 1000 gal/hr and 3/4" lines, it was just too restricted by the current coolant loop, it has since been replaced with a large Hydor. At this point it is probably easy for you to believe that the motto "Go Big or Go Home" really should be on one of the faceplates of HeavyBlue.

Tight fit in there huh?

It's only going to get more crowded, I am far from finished.

Reservoir, Water Pump, and a box that is the exact size of the peltier power supply.

Wait till the radiator gets shoehorned in there too, and this is just on the bottom level of Heavy Blue.

This is a float style water level sensor for the safety system.

Safety system you ask?

I told you, there's something that makes HeavyBlue special...

"Go Big or Go Home" in action, that will be my radiator.

These are heater cores for Ford F-Series pickup trucks, yes the guys at the auto parts store thought I had lost my mind. All of these cost me less than $100, you cannot find a radiator for watercooling this size alone, nor that cheap.

What, you thought I was going to connect them with hoses?

I soldered the four heater cores together and joined inlet to outlet with copper plates making channels.

Yes this radiator is massive, wait till you see the fans...

Oh yeah, the radiators are easy access too, they are mounted on a 1/8" cold rolled hinged steel plate.

I have to work on it, there better be room for arm...

Here is the radiator bolted to the plate and plumbed for the coolant loop.

No this is not an optical illusion, that really is an incredibly tight fit.

After I took this picture I went back to my notes and rechecked my math to make sure that the power supply main lugs would still fit.

It was close but they miss that giant conductive box.

Well I have to get coolant into the case somehow..

This is 1/2" Tygon with UV reactive coil sleeving for flexibility and kink protection.

Here the coolant hoses are routed along the cable guide and the power supply for the lights is installed.

I forgot to mention that HeavyBlue will have a lot of UV components.

Since the case slides out of the rack, i have to have extension cables for everything.

VGA, 2 RS232 (Serial), 2 PS/2, 4 USB, Sound and AC Power

It was a very full cable guide after I got finished with it.

When you use peltiers or TEC's, you need to have some serious power...

This power supply should do the trick: 15VDC @ 43A = 645 W

I better get a second job for my power bill...

Here is an overall shot of that power supply.

Looks kind of innocent doesn't it?

I told you it was a mess of cables, and that's after I tied then all up nice and neat.

In the bottom right is a control interface board for that safety system you are probably still wondering about.

At least this end of all those cables looks better.

All the standard I/O for the PC is accessible through jacks mounted in a panel on the back of HeavyBlue

Convenient huh?

And just when you thought it couldn't get more crowded...

I slide the case all the way into the rack, the hoses don't kink and no wires are in tension, looks good so far.

Big fans for the big radiator...

These are about 8" in diameter and were initially used in the machine that decodes MRI data.

These two fans move some serious air.

Fans got to have an enclosure...

Unfortunately I did not have access to a press brake or TIG welder. So sheet stock, angle stock, tin snips and JB Weld here I come.

That should bolt on to the back of the radiator mounting plate nicely...

Hey look, it did!

The PC I/O access plate, not the prettiest job but it works.

Almost finished, now I just have to install the computer in that top case and put the secret in the bottom enclosure.

Industrial, spartan, utilitarian, call it what you will, for a rack cabinet, I think it looks good.

What's that in the bottom you ask? That's Project BlackBox. Be sure to check out the computer mounted in HeavyBlue here or it might not make sense as to why Project BlackBox even exists.


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