CCBox
Page 4

Self-Contained Fan/Radiator/Pump
for Water Cooling my XP1800+/DDRram System
 
Project Started: 4/17/02
Finished: 5/02/02

Click on a little image for a bigger image
Outside view of filter
 
Inside Mesh and Filter
  The outside intake with A/C filter on it. It should be very easy to clean, just pop off the top cover, and blow it out. The mesh is non-restrictive, as the fan isn't all that powerful, but we'll see soon enough. The parts came in today, and they're exactly like I pictured, from all the pictures I've seen... go figure.
 
  This is the inside of the vent with the screen to hold the filter in place, and to protect the core from nicks and bumps.

  

 
Reservoir
 
DangerDen Maze3
  After getting the pump, I found there wasn't enough room on the top shelf to mount the reservoir, but there is a perfect little nook in the bottom front of the case. So, the top brass nipple is the inlet from the radiator, the bottom angled nipple is the pump intake, and the little shutoff valve should be fine for bleeding and filling. Liberal amounts of JB Weld inside and out on all fittings and the lid, that takes at least 15 hours to dry. The hard part...waiting. Good thing it's almost bed time, it'll be ready for tomorrow.
 
  The main event. Danger Den Maze 3. Soon to be installed, if there aren't any leaks tomorrow. This is a nice quality finished product. The Lucite top shows the rough surface area for turbulence, and has been leak tested to 85psi. Good enough for me. heh. The base has small swirl marks, but appears to be flat. I doubt I could finish it any finer with the 600 grit WetorDry I have, so I'm not messing with it. It's surprisingly heavy for as much area that has been removed. I think this might help in preventing rapid temperature changes on the cpu, as the mass retains some of the previous temperature characteristics. But, hey, I'm no engineer, either...

  

 
Back and Hoses
 
Top Rear with Hoses
  OK, I got up early Thursday, and got all the connections done in about 1/2 hour. Here's a shot of the back with hoses coming out the top.
 
  Looking down at the top rear mess. I used Industrial Velcro to secure the pump and reservoir to the case.

  

 
Reservoir, Pump and Hose layout
 
Front View of Reservoir
  View of front without cover on to access filling  
  Another view of Reservoir and Connections

  

 
3/8" T for bleeding air
 
The Leak Test
  The 'T' I had to use to get all the air out. The little valve in the reservoir just wasn't able to, no matter which way I rotated the box. Ah, well, much easier, anyway.     The Test. Not one dribble anywhere in an hour so far. Being the impatient d00d I am, I'll probably end up just running the leak test for a few hours and install this tonight. Had that problem with model cars, too, and half sticky glue everywhere, and runny paint. Some things never change. ;)

  I'll be testing for leaks today, and if all goes well, I should have the project finished Friday, 5/03, with some actual temps. I must admit, I'm not so much a hardcore overclocker as I am a modest o/c'er with a noise attitude. I could run at 139fsb all the time with no problems, but I hate the noise it takes to achieve it.

  I'm testing without the fan hooked up, no need, but I have to tell you, this pump is SO quiet, the only way you can tell if it's on is to touch it or a hose and feel a small vibration. It makes a small click when it starts, and that's it. I have a feeling this may be spooky at first.
Rear view finished
 
Inside view installed
  All hooked up, and running. No runs, no drips, no errors. Now for the real deal test - does it really work?     Here's what it looks like on the inside now. Very Spartan, you can even see ramsinks now, and the noise is OH, SO QUIET! I left two case fans in with the single contol knob I built earlier, and even with those on high, and the radiator fan on high, it's heaven.
   
Dynamic Duo
 
One Final Shot

  Here's the dynamic duo, just sitting there as I type this up. The temps are agreeable: It's a little warm here, and the system temp is 33 C and the CPU is at 38 C. I used Artic Silver 3 on the block and cpu, sparingly, of course, so we'll see if the temps drop any further. I ran United Devices (Distributed Client) for awhile, the highest the CPU temp got was about 7 C above ambient. I'm happy. It was well worth it. I didn't post any 'how-to's on attaching the block to the motherboard, but it's pretty much take your whole system apart, pull out the mobo, attach the nylon bolts and nuts as on DangerDen's site, put the block on, and tighten all nuts in a crosswise pattern until all springs are smooshed. I also used some Loc-Tite green on the base threads so the bolts didn't turn as I installed the block. Then, power up, and head for the BIOS for quick temp checks before booting XP. It's a good thing, Martha. Now maybe I can hear the oven alarm go off when my pizza's done, unlike last night....that's about it.
   I don't have any high tech thermal measuring probes, so all temps are from the motherboard. Was it all worth it? You bet. I'd do it all again if I had to, but I don't, because I can take it with me to the next main box. Total cost? Considering I scrounged a few things successfully, I have about $160 into it, the things I couldn't make. Worth it to me.
  Oh, guess I better find some floppy bay covers to finish it up, but the hard part's done. Time to weld   ;0) ~ Crow

  Friday minor update: I upped the fsb to 139 for 1600MHz, and for some reason, the temps are 2 degrees cooler. Hmm. I've been running United Devices all morning, cpu temp is only 6 degrees over ambient - at 33 CPU. I love it. But you know, I'm finding that noise is a relevant thing... now I can hear the radiator fan. hahhah... Maybe I'm just getting my hearing back from the 12 fan abuse I went thru until yesterday, who knows. But now that this project is over, I'll be looking for something else to do. The Danger Den block is so pretty, maybe a side window of some unique kind, if there actually IS a mod someone hasn't done before. L8Rz      It's been fun

   Update: 9/11/02 ~ I upgraded the cpu from an XP1800 to an XP2000. I also added two 120mm A/C server fans I scrounged from an old IBM server that are also tied in with the 120vac power. The Walmart fan, although it looked awesome, actually sucked about as much as my cat could, which is to say, not all that much. I removed the small reservoir and added a length of filler tube, turned the pump around, and now have the hot, return flow from the water block going thru the pump, to the rad, and the cool rad water going directly to the water block. I'm running at 145MHz fsb for a clock speed of 1824, and the temps are awesome.
   Ambient room temp is 24C, CPU temp is 36 to 37C. I'm thinking of purchasing and installing two high volume 120mm A/C fans to replace the Walmart pos, as there's still not a lot of air flowing thru the core. I just know there's going to be noise involved, though... ach. Still, it's not even half as noisy as it was with the 12 fans going I used to have.

   Update: 9/01/03 ~ I changed all the fittings to 1/2" barbs and installed 1/2" Clear-Vu tubing and the temps are now at 2 to 3C above System temp, a drop of about 4 more degrees C.  Worth the effort, and I'd advise you to go with 1/2" stuff right from the beginning. I also took the whole radiator assembly apart, and I used a 1/4" drill to make a few holes (about 200) in between the fins to improve airflow.  And, I added a reservoir made out of an old rubbing alcohol bottle.  This was an awesome improvement ~ filling and bleeding the air was amazingly easier, and much more efficient, as the air bubbles rise to the top instead of getting recirculated.
  Also, it seems silicon hose 'weeps' and that was why I had to keep adding more coolant as time went by.  The entirely closed system now does not need attending, no topping off, and I'm very happy.  The two 120mm a/c server fans are still humming along quite noiselessly, if that's even a word, and I hardly ever have to turn up the case fans.  I also used the new Artic Silver Ceramique, and it seems to be doing a bangup job of doing what it's supposed to do, a couple of degrees cooler than the AS3 I used before, and, it's cheaper, and you get a boatload of it. ;0) Ah, technology.

  I notice I still get hits to this set of pages, so if you have any questions or comments, feel free to email me. ~ Ken

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CD/LSP 2003