Project “E5NC” was conceptualized on Oct 25th of last year. The original intent was to build a system that would perform at a high level through the use of salvaged parts. When we started, our mantra was “high performance-low cost”. Well, 4 months later the project has been completed. The performance exceeded our expectation…as did the cost. What started out as a project that would have made Dr. Frankenstein green with envy, evolved into a very different monster. Salvaged parts turned into new parts. A relatively simple computer setup transformed itself into dual systems in a self contained environment. A single water cooling circuit became dual independent subsystems using TECs, the newest water blocks, 3 PSUs, and a remote water cooler. IDE drives were exchanged for SCSI raid configurations using Seagate Cheetah 3rd generation 15K hard drives. At the risk of sounding macabre; we loved every gory, heart wrenching, blood chilling moment we spent putting this machine together…we hope you like it too.

Part 1

In the beginning ExtremeMhz had a case…and it was good...

In the pictures below we present the CalPC “Large Server Case”:

The specs from the manufacturer's site:

• Has Sixteen 5.25" Drive Bays Exposed
• Optional Two Internal 3.5" Drive Bays
• Heavy Duty All Steel Construction
• Dual Motherboard Capability
• Accepts Two Power Supplies, or Two Hot Swap Power Supply Systems.
• Lockable Front Door for Security
• Includes Four Locking Casters
• Accepts up to Seven Cooling Fans
• 32½"H x 14¼"W x 25"D (with Casters)
• Weight = Approx. 70 lbs

The pump of choice was one that had served us well in the past; the Hydrothruster Q2 magnetic drive pump.  The Hydrothruster has one pump head on each side of its electric drive. The combined flow of both heads is 1050 GPH at a one foot height.

The heater core we resurrected for this project is the following:

**click to enlarge**

Heater cores are excellent choices for water-cooling. The dense fin designs these radiators have enable them to dissipate heat more effectively than the more common tube and fin design. The size of the radiator (in terms of surface area) directly impacts its ability to manage heat.  

This heater core’s specs are as follows:

• Fin area: 9-7/8" X19-5/8" X 2"  
• Overall: 14" X 11" X 2.5"
• Mounting plate
• 5/8” inlet and outlet fittings

Our intention was for these 3 components; the case, pump, and heater core to lay the foundation for this project.  Unfortunately, it was not to be.  Our first mishap occurred with the Hydrothruster pump.  It had seen its better days, and ultimately would not be able perform as we had hoped it still could.

Next: Parts 2 & 3