Cooler Master HAF 922 Case Mod

[MonsterMawd]

This was my project for Stompfest, the canvas was the Cooler Master HAF 922 midtower





I'm using paper to make a template for 2x 120mm front intake plate.


Tracking template onto 1/8" thick aluminum sheet.


I used a Jigsaw with 18 TPI metal cutting blade to cut the design. I will refine and finish the cuts with a hand file later.


The 1/8" thick aluminum won't fit in my bending brake, so I used my bench vise to bend the aluminum.

I'm using a Mouse sander with medium Grit sandpaper to remove all of the blemishes and scratching in the surface of the aluminum



Aluminum plate surface is finished. Next step is fastening it on with pop rivets, more on this soon!






I've attached the new bezel plate on with pop rivets.



Overkill "Nautilus" 120mm fan grills, http://www.mnpctech.com/120mm_Overkill_Fan_Grills.htm





In order to use the Knock-out punch, you need to drill a 2" pilot hole.


Greenlee Knock out Punches
Greenlee part # 730EBB-120 Last time I inquired, they were around $450 in the states + Large 3/4" socket wrench, and 2" socket. I wouldn't use anything less than 19" long socket wrench. Estimated purchase price of $550 new.

[xeromist]

Yeah, the punch does look a lot easier than a jigsaw or hole saw. Someday when I have money to burn... 🙂

[MonsterMawd]

Holesaws will suffice in meantime!

The bezel temporarily attached

[pcjunkie209]

That looks sick! Great work. 🙂

[MonsterMawd]

Thank you junkie!


Better open up the rear exhaust for improved airflow as well before the chassis gets painted.


Rear exhaust grill on the HAF 922 chassis


Low tack masking tape (Scotch brand Painter's tape)


120mm Nautilus Fan grill
http://www.mnpctech.com/120mm_Overkill_Fan_Grills.html


Trace the inner opening of the 120mm Overkill Nautilus fan grill


Using Jigsaw with 18 TPI metal cutting blade.



I masked off the face of the Nautilus grill, then painted the inner walls of the openings with Black self etching primer. flipped it over, and painted the backside as well.





I then removed the masking tape and held the can roughly 16" away from the grill and sprayed the perimeter of it. This is how you achieve the speckled paint effect.







Rustoleum's Grey self etching primer. It reminded me of Military Grey.. I love the color.





I call it Alien camouflage ..heh

[MonsterMawd]

Here is the XIGMATEK XLF-F1254 120mm White LED Case Fans. These are rated 1500 RPM @ 61 CFM. Noise level is 20 dbA





Here is the custom HAF 922 front bezel and fan grills after receiving 4th coat of Charcoal Grey Metallic paint. The finish on the bezel will buffed out.

[MonsterMawd]

I'm installing the machined Diamond Knurl computer case feet on the HAF 922's PSU location is on the bottom, so you've only get 3/16" space for the fastener nut. I trimmed down 2 of the included 8/32 machine screws, to use these feet in the 922.

http://www.mnpctech.com/Aluminum_Computer_Case_Feet.html



I used 7/64 size drill bit for 8/32 size machined screws included with case feet.


Dusted the tops of the feet from 20" away with Black Self-etching primer... The bottoms are pure Black


Painted the 140mm fan grill.. should have done same effect, looking at it now.. oh welly!

I've also installed Acoustical foam in the HAF 922 chassis yesterday, starting on the backboard. It has Adhesive backing for easy installation. It cuts very easily with a scissors or Xacto knife. This foam will help dampen noise generated from inside the 922.

http://www.mnpctech.com/Acoustical_Foam_Sheets_PC.html



Painting the side panels...

[MonsterMawd]

"LAN Terminator" dude surrounded by circuits hardwired into the system inside.











U-channel window molding, http://www.mnpctech.com/UChannel.html





I use the Clear 3M 4010 Heavy Duty Tape, http://www.mnpctech.com/scotch_4010_tape_of_the_casemod_gods.html

[MonsterMawd]

The case is done...

[xeromist]

I'm not really feeling the caution tape but the rest of the paint is sweet looking 🙂