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Expand your case

Expand your case

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Published by: Alan D Cobourne-Smith on May 22, 2008
Copyright:Public Domain

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04/14/2011

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Expand your case
Adam Piper explains how to create a home for a second PSU or expansive water-cooling rig by simply boltingtwo cases together.Short on room in your case, but can't justify the £100 needed for amammoth Cooler Master Stacker chassis? Never fear - you can save a lot of cash by just bolting two cases together instead, and then spend your changeon faster components. In this guide, we show you how to make a mini-case toattach to a main case. A mini-case is just a regular case that's been cut downto provide extra space for additional components, such as a second PSU or water-cooling rig. You'll need two identical cases (which we managed to findsecond-hand for just & pound;10), and the end result will take up the sameamount of desk space as a regular case.What you need:
Jigsaw or Dremel (or equivalent rotary tool).
High-speed steel (HSS) jigsaw blades if you're using a jigsaw. These cost around £6 for three, butthey last for a long time.
Smooth-cut file. This is for smoothing off the sharp edges on the panels.
Ruler and pens. You'll need to do lots of marking and measuring to get this mod right.
Drill with 4mm and 6mm HSS drill bits. These bits are for removing pop rivets from the case.
Loads of M6 nuts and bolts. These are used to secure the two cases together. You'll need eight sets(nut, bolt and two washers) or more.
3mm pop rivets and gun. These are needed for attaching any pop rivets that you might need to replace.
Setsquare. This provides a perfect 90- degree rule, which will ensure that your cuts are level with the case'sedges.
Corner braces (otherwise known as L-brackets). These are used to connect one case to the other.
Automotive paint and body filler.
1,200-grit wet and dry sandpaper.
Goggles.
 
Expand your case 01
Remove as many loose parts from the two cases as possible, including all the panels (apart from the roof) andany hard drive cages. Decide which case you want to cut down, and whether it will be on the top or the bottom,and then load up your drill with a 4mm HSS bit. It’s now time to start removing any internal parts such asmotherboard trays or drive bays. If these are riveted in place, you’ll need to place your drill bit on the top of therivet and drill slowly. When the drill has made a dent in the rivet, you can then speed up.
Expand your case 02
 
If you need to remove the roof of the case while you’re drilling out the insides, bear in mind that this will causethe case to become floppy, and it may even warp. For this reason, you need to hold the roof in place usingsome nuts and bolts (or pop rivets) once the parts have been removed. The next step is to decide how muchextra space you need for you rig. If the space is needed for a specific part, such as a water-cooling radiator,measure the radiator and add around 20mm to the measurements; this should provide plenty of space for thepart.
Expand your case 03

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