Sorry about the pictures half way through the project. The camera was in storage and couldn't get to it until half way through :S
Step 1: Brain Storming
So I ended up walking around the house checking out this and that. When I came across the fireplace grate I thought that would work the best and it had a simple design. :) Grate it is.
I scrounged round the house and gathered some old copper tubing from an old plumbing project. Found all kinds of shelving, scrap wood and other planks from various home improvement projects that my roommates had done.
I didn't technically measure how high I wanted the grate to sit from the base board so I did it the good old fashion way...Eye balled it and figured I was going to put som fans in there (80mm computer case fans).
Step 2: The Layout
Okay so yah I made the layout in MS paint :)
That's the bottom with the CPU in the back left...
So these are the hotspots and the placement of the vertical rods were dependent on the whereabouts of the hotspots. I tried to get 2 copper pipes on the CPU&RAM; while having a sing pipe directly down the middle with one slightly to the right and then one directly on PSU.
Step 3: Cooling Process Layout
Anyways back to the topic. I decided to go with 2 80 mm fans 1 directly under the CPU, RAM and graphics card area. Then the other fan to over lap the mid section and hit the Power supply area.
I never used a router before but it was really easy and a lot of fun. I'm sure google or a wiki will provide what it is and the use of it. Basically it lets you cut away wood from the inside out and whatever depth you want. Provides the nice little indent for the fans.
Step 4: Soldering 101 - Putting Together Metals
Back to the copper piping. Making the grate.
*** Important: use a wire brush to clean the areas that will be soldered together. FLUX, must have flux! Well I heard you can sneak by without it but its so much easier with it. Flux helps the solder stick to the copper and fuse the 2 copper pipes together. Propane Torch to heat the solder and the copper piping for the whole process to work.***
Again safety first.
Make sure you are working in an area that doesn't have any flammable items. Heat resistant glows, eye protection, knowledge or a helping hand that has don it before. :) It was my first time with this process so I had a help. Still a fun process.
I ended up drilling some holes in the copper tubing (copper is a soft metal allowing the drilling.) so that I could screw the piping together and to make sure the grate wasn't going to leave the base board. :)
I would recommend taking the copper tubing off the base board if you want to avoid the black scorched marks and the possibility of well messing up the base board. :)
Step 5: Cutting and Forming
I traced the laptop onto the base board (high tech huh?) then I gave a half inch of room around that traced area. With the laptop on the grate I measured how high should the front board be. Again I eye balled it until I actually found my tape measure.
I was looking to have a round edge that would compliment the rounded edge of the front part of the laptop.
To make the front board rounded I cut it on several angles using the table saw. Once at 30 degrees front and back then 10 degrees front back.
*** If you don't feel comfortable using a power tool such as a table saw track someone down that does. Better safe than sorry. ***
After making the cuts and a goof pile of saw dust :) I busted out the power sander.
I didn't have a metal file available so I used the sander. Probably not the best choice (need a rough grade sand paper to do it effectively) but it worked. I had to grind down the screws from the grate being screwed to the base board.
Step 6: Continue Crafting
In the last step I did a bunch of cutting and forming of the wood portions. When I put everything together I wanted to allow a slightly raised platform for the base. This would provide airflow into the fans on the bottom and help give some comfort to the user, even if he/she decided to put it on their lap. Its kinda heavy but it still worked out pretty well. So I took a piece of old shelving wood that has a plastic coating on it and cut a 10 degree angle on the front to be screwed to the grate base board. I also wanted to provide support to that grate base board and the actual base so I cut a small block with the same angle the be placed in the middle of the fans in the back.
I screwed the block in from the bottom (1 screw) and from the top (2 screws). I had to go in and sand down the screw head on the bottom cause it wasn't sitting level, no worries.
I used screws throughout the whole construction because they hold better than nails. Drill holes before trying to put the screw in, 1 to avoid cracking and 2 it helps set the screw better.
The only things I actually had to spend money on were the brackets that add support the the front board and offer guide braces the the sides and back when the laptop sits on the copper tubes. I used gaffer's tape because it don't get gooey like electrical tape and it's fabic feel is more appealing Its kinda an eye sore so I may change it later.
I used horseshoe shaped staples to tack the electrical wiring to the base so that its not flying around. I'm thinking of using velco to hold the fan wiring down too.
Step 7: Wiring and the Soldering Iron :)
There is an instructable on "wall warts" Reuse "wallwart"
This one helped with the soldering too. a twofer :)
*other resources stated at end of this instructable*
In a nutshell and without the math.
Plug in the soldering iron before starting steps. This will give it time to heat up.
Please make sure the soldering iron is the only thing plugged in while working with the wiring.
This example I have 2 fans.
Give yourself a bunch of room on the wires just in case you goof.
1. Strip the negative and positive wires to just the exposed copper wiring. Keep track of the + and -
2. Twist the 2 + positive wires together (red wires).
3. Repeat step 2 for the - negative wires (black wires).
4. Take your wallwart / power adapter and cut off the round tube-like end. Please make sure it isn't plugged in. Strip those wires down keeping track of the positive (red / +) wire and the negative (black / -) wire. *In my case it was a black cable with a white line down the positive wire (ground which is the positive).
5. twist the wallwart positive cable to the other twisted positive wires.
6. repeat step 5 but with the negative wires.
*Wire Check: you should have all positive wires twisted together and all the negative wires twisted together. Before using the solder plug the wallwart in keeping hand and other objects away from the exposed wiring to test the fans. Most computer case fans won't spin in the opposite direction if hooked up wrong. They won't spin at all. If it doesn't spin then double check the wiring or double check the fan itself. Once all fans are spinning then proceed*
7. Bust out the solder and the soldering iron. Take the twisted wiring of positive (should be 3 wires total), hold the iron against the wires and bring the solder to the iron so it will melt onto the wire fusing them together.
8. Repeat step 7 with the negative wires.
9. Once the wires and encased in solder and cooled, you can use electrical tape the wrap up the solder casing OR use the black tubing shown in the picture. Its the same thing basically. Use the soldering iron to melt the ends of the installation.
10. Final fan test. If they don't spin then there is a goof and you'll most likely have to start over. :( If they spin then you are golden.
I was going to put in a math versoin but I really didn't do much math other than rereading the above instructable links, double checking the voltage on the fans and what the power adapter said.
1x 80mm = 12V
1x 80mm = 12V
+ --->)---- - Is the direction of polarity. read instructables or wiki it for further assistance.
Input: 100-120V ~.5A
Output: 12V -------- 1.0A
I figured that the amperage was 500mA and would do the trick for two fans.
The reason why I didn't do it with the USB connection I have was because it wasn't enough power, even for a small fan. I used several sizes and I wasn't getting the airflow I wanted.
If you are doing the USB hook up then its just like using the wallwart but instead you cut the end off a USB cable.
Step 8: Test and Credits / Resources
The noise level is ehh tolerable. Its like sitting next to my desktop so its not a big deal for me.
The front board covers the speakers but one doesn't work and I have to wait for a year to past so I can get into it. Still under warranty :( Oh well, I use headphones anyways.
Credits / Resources
Brainstorming and finding info:
First Instrutable I came across.
The DIY Laptop Cooler
by slater101on Jul 9, 2007in tech & craft
DIY Laptop Cooler
by silverHaloon Mar 16, 2006in tech
Wiring and Power
How to Build a Bench-Top Power Supply
by greyhathacker45on Jul 8, 2007in tech
Reuse "Wallwart" transformers
by pir8p3t3on Jan 21, 2007in tech
Thank you to those that posted their instructables.
Be careful while work on any project. Its best to be safe than sorry. Please be careful with any tool you handle. Take your time, haste makes waste and can cause accidents. Be very mindful of electricity. I had a helping hand with my project and if I felt uneasy then I asked for help. This is meant to be a helping guide, if it doesn't work the first time give it a try again. :) Just be safe, I can't stress that enough. Happy crafting.
Let me know what you think :)