more more we want more...........
hurry up LOL...
Looks good:)

Just a quick update...  Got the surface smoothed out, and added a depression in the center which will be under the bars, and that will continue on down to the back panel.


Just for fun I set the bars back in place and tossed on the oval decorative pieces for a look-see.  I happened across those at the local auto parts store in the dressup section. :thumb:


Ok back to it...

Still working on the top panel, but it's been in a holding pattern until I can get a good dry weekend to do some fiberglassing.  (which might actually be this weekend <crosses fingers> ).  In the mean time, I've been skipping ahead to the front grill.  So here is some of that progress:

Using 1 1/2" x 1/8" aluminum flat bar, I cut 18 pieces down to size.  This is the first half.


Next I started rounding the bottoms to match the curve of the side panels.


The cutting is followed by the filing.


All 18 pieces rounded.  A bit more work is needed to get them all the same.


Next step is to drill mounting holes through all pieces.  I wanted the grill to come out more in the center, so I staggered each piece by 3/16" before drilling.  I double and triple-checked the spacing, and made sure the pieces were square at the bottom before clamping them together.


the 3/16" offset was about the max I could go, leaving me with a 1/4" between the hole and the edges of each end piece.


Half of the grill done, with temporary acrylic spacers added just to see how it looks.




Looks pretty good, now to do the other side.  You can also see my badass cardboard mockup of the front bezel where the lcd screen, fan controller, and key switch will go.


Repeated the same process for the other side, and assembled all together.  I love the stepping!


And finally, a shot of the whole thing in place.


Can't wait to get the top edges done, and the whole thing polished up.  It's gonna look shaweet!  :)

Niceee Boddaker the grill is already looking awesome. U going to polish the front only or also the sides of the grill ?

alain-s

Niceee Boddaker the grill is already looking awesome. U going to polish the front only or also the sides of the grill ?

 
Thanks alain.  I'm planning on taking a whole box of parts to the chrome shop:  Top bars, bottom bars, front grill pieces, and maybe the stainless hard lines too if I don't feel like polishing them up myself.  :)

More Grill progress...

Made my own metal spacers from 5/16" stainless steel tubing.  I took this shot before I deburred the ends.


And I got the top ends of the bars rounded.  This was kinda tricky since they are offset, and I needed to have the all curves end in a straight line so it will mate up with the top faceplate.


Here's a couple shots of the grill on the case..




And an over-all wide shot.


Hoping to have a productive weekend, as the weather should be very nice.

Cheers!

davestune

dude that's going to look so sweet, what color are you going to paint the case?

 
I'm thinking a candy orange, with maybe some subtle ghost flames.  Something along the lines of this color:

 
or more specifically...
 
 

malVizio

wow! is there anything left from the original case?
lol!! great job! can't wait to see it done!

 
I think the only things left from the stock case is the frame and the outer side panels.  Pretty much verything else has been gutted. Some parts are getting repurposed tho. 
 

I think your choice of color is good but a powder coat form of that color should be more to your liking I would think.

With the economy being bad right now several auto stylists/paint shops have opened up their business to paint just about anything. Money is money.

This build continues to look great.

I'm your ghost flames Guy.
Photobucket link http://s306.photobucket.c.../Airbrushed%20Projects

What's this??  A Cosmos Cruizer update??  :shock:

Yep, believe it or not, some progress has been made!  Now that the Maker Faire PC is all but completed and ready to be delivered to NVIDIA, I can continue work on this.  I'm really going to push to get this thing done, without any more breaks.  So there will be a steady stream of updates from here on out! :)

I've been slowly working on several components of the build simultaneously, one being the side scoops.  I've got the form re-prepped to 'glass the second one, and I finally got the first scoop attached to the panel.  I mixed up some resin paste and, after cleaning the surfaces, gooped it on the edges of the scoop and set it in place.  Then I applied more paste all around it, inside and out.  I used a 2" acrylic disc I had lying around to scrape off the excess paste, leaving a nice rounded fillet between the scoop and the panel.


I used a wooden dowel to get the inside edges.  And I always employ the highest tech, state-of-the-art clamping/holding devices available to keep the parts stationary while gluing.  ;-)


After a few hours, the paste had set up so I could remove the hi-tech holding device and put the panel on the case for a look-see.


This weekend, I'll do a little sanding and hit it with a coat of primer to see how it looks.


Feels good to be back at it.  woot!

NzXtguy

I kinda like This idea, I am currently building a pc into a new desk im building, Have constantly been wondering how to wire the power/reset.... mhmmm maybe i can get more understanding on this as u go threw with it and i might steal the idea :)
If u don't mind of course.

 
No, I don't mind at all.  It's not like I'm the first one to employ a keyswitch into a mod. :)  I'll be getting to that part shortly and I'll make sure to fully document the wiring (as soon as I figure it out myself lol)
 
 

So over the weekend I managed to cross a HUGE item off my to-do list... The Suicide Door!  :D

Anyone familiar with the Cosmos II doors will know they are a royal PITA to do anything with because they are so complex.  Just adding a basic window is a massive undertaking due to the door's varying thickness and compound curves.  Well, not only am I adding a window, but I'm also relocating the hinge point of the door from the front of the case to the back, mimicking the old "suicide door" style seen on many custom rods.

This modification affects not only the door itself, but the side bezel and case chassis need to be altered as well.  But first up is the door panel.  I took the left door, removed the aluminum door skin, and flipped it so the solid part was at the bottom.  But in order for the hinges to work properly, I had to harvest it from the other door.


So I took the dremel and separated the hinge from the donor door.


Marked its new position on the back side of the new door.


After removing that portion, I did some test fittings until the new hinge fit perfectly.




Then I glued it into place.  I screwed the metal hinge in temporarily to give it more rigidity while gluing and to check for level.


After the initial tacking set up, I used some ABS cement to fill in all the gaps and add reinforcements where needed.


Once the new hinge was in place, I turned the door over and started marking out the window.  I added the side scoop on for a quick visual.


After I was satisfied with the window arrangement, I proceeded to cut it out.


Next I prepped the core for foam by taping off the window edges and roughing up all surfaces.  Adding foam in the center will allow me to re-skin the door in fiberglass, and also aid in sound deadening.


Let me just state for the record that I despise spray foam in a can!  You can never use this crap more than once or twice, otherwise the tip gets clogged, rendering the nozzle useless. So you use a screwdriver to try and clear the passageway, and you end up breaking it off, sending spray foam all over the garage!  (TIP:  If you get spray foam on your clothes or in your hair, wait until it cures before attempting to remove it.  Much easier! lol )


After the foam cured, I took a hacksaw blade to carve away the excess.


I was able to use all the ribbing as a guide to get the foam flush.


And a quick final shot of the door on the case...


Next up I'll get to the door frame and chassis modifications.