I decided to make some aluminum and plexy cover panels for the Cooling Towers, I will use the aluminum for the bottom and the top.

I want to use chrome nuts exposed to the outside, they'll stand out on the black background, something like this:

I cut these aluminum parts for coverage by a sheet
 
    
 
In the panels that I'll place on the bottom of the towers I made the opening for 1 140mm fan,
 
   
 
  
 
  
 

 
At this point to clarify what I have in mind here is how the new bottom structure looks with 6 input 140mm fans
 
  
 
I will create an interspace for the fans with this beautiful profiled of 2.5 cm 
 
   

another update, as first thing I fixed the central structure over the 900D and between the 2 Cooling Towers using 25mm screws and nuts. I fixed the structure with clamps so that it was in correct position.  I have marked the points where do the holes, drilled, passed the screws, initially thought to fix it down even to the 900D but it is not necessary.
 
   
 
And here is the result, notice how the parts are perfect on top
 
 
 
 
Remains the central part where are 4 140mm fans. I started always from a profiled of 2.5 cm x 200 cm, I cut to size using a Dremel to 55.6 cm and I did a placement test.
 
  
 
I fixed the 2 bars in place with clamps, I marked the drill holes so that the screws don't obstruct tthe later step and I screwed with 20mm screws 
 
    
 
And here is the final effect
 

 
Disassembled the entire structure I  returned to work on the central body more easily. In particular, I started working on the side supports for the 4 140mm fans.  In the 900D here are 4 120mm fans so I must saw itaway and rebuild custom. 
I used L 25X10 mm profiled , I cut to size (55.6 cm) using Dreme, a bit of file and now I try only the positioning.
 
   
 
With the fans between the two profiled the effect is that, the profiled have yet to be finished, but this is the next time!
 
  

to facilitate placement of the side fan block I sawed facades side of the 900D, leaving only the bare minimum for fixing Cooling Towers, about 1 cm.
 
 
 
I put the paper tape on the facades of the case.
 
 
 
Given that these are in contact with the sides TdR to avoid removing unnecessary parts, outside there is in fact  the aluminum profiled, I reassembled the 3 parts and marked along the Cooling Tower profiled  the protruding parts of the case.
 
 
 
Once I have removed everything I cut the  marked parts
 
    
 
Now the side fan block has the possibility to come out sideways of about 2 mm per side.
 
    
 
Finally I tried to compare the space inside with the original  PSUs supports, as I suspected, I cannot put the 2 PSUs on the same side, I'll put one front and one rear. 
 
The solution of putting all 2 PSUs on the same side although more traditional,  in reality convince me less because it would have gone to impact heavily on the air flow creating a block.
 

I have therefore better equipped me, I found two cups 64mm and 60mm, here I make a comparison with the hole in the old piece with the hole of 64 mm
 
  
 
You will not believe but the 64mm cup, which seems perfect, makes a hole too wide, where I haven't margin to fix the hole with the file, also because there are the mounting holes around. Instead of the 60mm cup, who leaves 2 mm on each side to remove the file by hand with give a perfect result! 
 
I have redesigned  support  putting the filter behind with the attacks upwards, I opted for a square hole to fit the screws holding the glass.
 

 
I modified a bit the technique used previously, I drew the design on the panel, made ​​a hole in the center of the circle, used the 60mm  cup for the circular opening and the Dremel for that square.
 
  
 
A big  file work to remove several mm in both holes, I must admit that I'm re-evaluating much of the  file work, you can obtain a considerable accuracy. 
For the mounting holes for the filter there are no problems just mark them, for acquatube this time I was much more accurate, I have done a  in holes calque with a paper and pencil and then I cut the inner circle corresponds to the size of the glass.
And here is the result, after subtracting 2 cm margin to fold for fixing, the 3.5 cm will allow me to put the 90° connector or make a turn with tube.
 
    
 
One particular thing I want to highlight this project is that I have to make the pieces more times: towers are 2; supports for the Monsta are 4; the supports for the 4 fans are 4; openings  for 4 fans in the case are 2 and so on.
 
Also in this case found the method and made ​​the piece, in reality I must do 4 of its.
I used the first made as a template, I fixed with clamps, marked in pencil, mark the center of the circle, drilled with the drill, and then I used the same technique used previously.
 
and two
 
  
 
And 3, and 4
 
 
 
 
 
But it wasn't so easy, I have therefore accumulated some wrong pieces , but I had the satisfaction of seeing the look without the paper and film.
 
 
 

Still a bit of work to file
 

 
I marked on all the  pieces a 20 mm edge and 45 mm from the corners, a part that I have to remove so that the piece  fits on the Cooling Tower where in the corners there are the L-type brackets, which are precisely of 25 mm. 
 
 
 
I folded the pieces to get the form suitable for fixing
 
     
 
I have tried the supports in their slot and have to say that perfection was what I wished
 
 
 
To get an overview I put all the parts in place, here's a front and rear view, plus two from the top.
 
   

I realize the supports for 4  front 140mm fans and a fastening system.
The fastening system that I thought having to anchor the 900D original front frame, instead looks great anchored to the structure of Cooling Tower as I tried last time.
 
But I cannot fix a bar posterior to the vertical profile of Cooling Tower, as I had originally thought because protruding to the inside of some mm over the fixing screws, so probably it would touch the radiator, so I thought of another solution .....
 
But from the beginning, I realized the fan supports 
 
     
 
I also did a trial installation of the fans on all the pieces, I was very pleased indeed all the pieces were perfect on the first try and did not require adjustments.
 
  
 
At this point I realize the horizontal bars that I will use to attach the fans supports to the main structure.
 
   
 
To make the bends I used a Profiled of 2.5 cm as a base and one of the cut pieces as a block. 
I repeated the operation and I got the desired result! 
 
    
 
Then I passed to make placement tests
 
  

I then worked on the rear panel with the slot for the Mobo and VGAs, I removed it
 
   
 
and I fixed in its new location
 
   
 
I then perfected the rear opening for the 4 140mm fans, removing part of the edge
 
       
 
this is the result
 

I then modified the front where now will be 4 140mm fans
 
                 
 
and here's the new piece fitted
 
 
 
 
These are the two fronts that I want to become equal
 

 
so at work!
 
    
 
On these parts I also want to add a LED system, which illuminates laterally
 
 
 
I therefore build the support for such LED system
 
          
 
and I have fixed one of them on the frontal
 
       
 
here is the final effect
 
    

EVGATech_ErinW
That thing is either going to take down the local power grid, or the Servizio Meteorologico will come after you for altering local weather patterns with that many fans.
 
Very nice.

 
Thanks Bro, you're absolutely right!
Also consider the red flash unleashed !
 

Meanwhile, inspired by the legendary (and crazy) Bill Owen of Mnpc Tech (do you know him ?  )
I designed to realize removable grille covers on all the houses of this kind:
 

 
However, I haven't found in Italy the perforated sheet such as that used in the work by Bill (with 4 mm hole, 5 mm pitch, Offset of 60°, 1 mm thick, preferably aluminum), in huge quantities and good price.
I then found an Italian site, OIB, which makes customized metal sheets and I've ordered a huge quantity, 4 mq cut into 4 sheets of 1 x 1 m.
 

 
I also designed the several aluminum frames to be ordered from lasermio.it
 
  
 
The sheet ordered by OIB, that fully meets expectations, notice the difference with the one found in the hardware chain,  the % full / empty is very different:
 
 
  
 
and cames the parcel from lasermio with frames
 
       

But we move on to the creation of the famous grids 

 
I cut and clean the perforated sheet mesh
 
    
 
put in place and glued with bi-component
 
     
 
And here's the first grid ready!
 
Bro was so much that I wanted to do it ! this idea was born even before the project's Mod, thanks to Bill Owen for having unleashed the monkey! 
 
 
 
Some tests
 
   
 
On the outside I have perfected a couple of details which I was not satisfied
 
  
 
I then placed the outside grill, blocked, drilled and fastened.
 
  
 
I went to take care of the  grids of the 2 single fans positioned on the bottom of the 2 Cooling Tower :

 
both internal grids:
 
     
and external:
 
   
 
And here is the result of 4 grids 
 
the internal
 
  
 
and the external
 

 
I'm then going to try them in their final position
 
   
 
and then positioned it on Coling Tower, remember that this is the bottom, the tower is upside down in the picture
 
 
 
I wanted to reassemble the Monsta 560 to see the real dimensions.
Here is the Coling Tower with the Rad mounted and bottom fans block mounted.
 
  
 
To position the grid I had 2 options, higher than 2 cm wire of the section, it would seem more beautiful and clean as a solution but it is very close to the RAD and didn't convince me much
 

 
or lower than about 2 cm above the base, this solution leaves few cm above, it has the disadvantage that the screws of Coling Tower clutter up and that the grid could touch the fan's fixing screws.
 

 
I chose the second solution, however, and I went to modify the grids
 
   
 
The grid at this point fits perfectly between the profiled in the bottom of the Cooling Tower
 
 
 
The grid is however so in contact with thefan  fixing screws 
 

 
I have, however, planned to use the rubber adhesive under the grids to prevent vibration, so I thought if I put 2 layers instead of 1 maybe they are sufficient 
 
I then tried
 
    
 
And it work. I am then passed to fix the grids to bottom cover of Cooling Tower, but I had to move a couple of screws on the main piece
 
    

Here, finally, the working of the last grids, cutting of perforated sheet

 
These are the ones that cover the fans output from Monsta 560 mm
 
   
 
This big is for the top of the case, I do not know if I'll add something here
 

 
I will spare you the working, but I'll post some photos, and I assure you that saw so is very impressive
 
     

Then finally the package from EMF arrived
 
     
 

But as I said it was a test, and in fact the measures of the holes were not perfect ..... 
So correction of design
 
     
 
Here is then a forecast of the plexy pieces we're going to do
 
   
 
 
I also started a mini-project for the illuminated plane
 

 

I dedicate myself to the structure 
 
I have taken measures
 
    
 
and started cutting and assembly
 
           
 
some test
 
 
 
In practice I put a strip Led in the profiled, under a sheet of mirror plexy to maximize the effect light  (which will insert the open side) and above a slab of red plexy, which should give a diffused light effect. 
I also did a test with a panel of white plastic that I had.
 
  
 
The final touch on the open side
 
     
 
And here is the full support of the illuminated plane
 
   
 
 
Other small modifications, as to the support of the fan block so let pass the cables through
 
 
 
Here is the part mounted, it blocks the fans and serves as a support for the illuminated plane
 
     
 
Now also allows me to pass the cables in the back
 

I improved support for the PSUs, so that it takes raised about 2 cm, this allows a circle of air also from below, is also fixed with 4 screws in the corners and is therefore removable.
 
       

Meanwhile C3r34L KilL3rs from EMF going to quote and correct the drawing that I had sent him
 

 

I then went in person to one of the secret  locations of EXTREME MODDING FACTORY , where I finally met the legendary C3r34L KilL3rs that welcomed me and brought meinto the Modder's Land of Toys.
 
And in the end we have developed a prototype perfect!
 
      
We repositioned the openings about 2.5 cm higher and the overall look is finally perfect
 
  
 
Finally I want to give you a treat, two photos stolen from the secret site of EXTREME MODDING FACTORY  in the middle of our brainstorming
 
 

Guys, now I want to make a point of the situation and thank my sponsors
 
In primis the 2 :
 
MAIN SPONSOR: EXTREME MODDING FACTORY
(Thanks to C3r34L KilL3rs and Tombino-)
 
that sent me various parts designed together
 
https://www.youtube.com/watch?v=4-qOWZJcAXU 
 
MAIN SPONSOR: ENERMAX e LEPA
(Thanks Benjamin)
that sent me  38x UCTA14N-R (T.B.Apollish Red); 16x UCTB14B (T.B.Silence 14cm); and 1 PSU LEPA G1600 
 
https://www.youtube.com/watch?v=MfnV0UwE4Lg
 
I also made ​​two orders from my 2 Secondary Sponsor, which are:
 
SECONDARY SPONSOR: AQUA COMPUTER 

(Thanks Sven) 
2 Aqua Computer Aquero 6Xt 
3 Aqua Computer Aquatube G1/4 Silver
3 Aqua Computer Steel Filter
2 Aqua Computer Flow Sensors, 4 T water Sensors, 8 T air Sensors
4 Aqua Computer D5 pump motor with USB and aquabus interface

SECONDARY SPONSOR: AQUA TUNING Italia e Europa 

(Thanks Alessandro) 
4 Alphacool Monsta NexXxus 560
8 splitter 8x Phoyba (& cables)