(Warning, if you are allergic to, or offended by the sight of copper you should close your browser immediately.  Failure to do so will result in immediate copper exposure.  All images are hosted on photobucket)
After months of planning I present to you, the first 100% copper SR2 waterblock:
 
This project started off with the most humble of origins (http://forums.evga.com/tm.aspx?m=407222), but after building a CNC machine in my basement from scratch you can see the results.  (The CNC build will be its own post one day) 
 
 
 
Prototype:
The prototype began with the most unusual of materials, foam.
 
The idea was courtesy of RBIEZE.  Its far cheaper to make stuff out of foam, then even Aluminum.  Plus it will never break an end mill.
 
Once I get what I like, I made one out of aluminum:
 
I used a scrap piece of Aluminum so there are random holes, and other marks in the material.  One can only go so far with foam, but you need to drill and tap to make sure holes line up with the motherboard.  Aluminum > Foam.
 
 
 
 
Construction:
Once I got what I was looking for comes the copper construction.
This is what we start with, a huge slab of copper:
 
Here are is the hole drilling process.  This way I can screw the material down as my machine cuts out the part.
 
Then comes the next step after drilling, milling:
 
 
First I mill the inner channels. 
 
Air compressor cleans things up nicely.
 
After the inside is done, all that is left is to mill out the outer shell:
 
This is the first plunge cut and will wrap around the perimeter of the part.
 
All done:
 
 
 
 
 
Clean up & close up:
 

 
 
 
 
 
  Sandblasted:

 
Installed:




 
 
 
 
 
VR Block for CPU 0:
As usual, we start with a prototype.  This time I said why not, lets go straight to aluminum.
 
   
Mounts nicely:
 
 

 
 
The parting shot:
 
 
EDIT:
So in an effort to clean up my photobucket, I made some folders, and apparently it broke all the links, so I just re-posted all the pics. 
 
EDIT X2:
Here is a 2015 update:







 

That looks really good!!  What is it sealed with, Permatex?

VistaHead

That looks really good!!  What is it sealed with, Permatex?

Thanks!  yes, I designed this one for Permatex. 

Awesome job Nate!!  If ever was a post that deserved multiple Blue Ribbons....this is it.  I remember reading that post a while back...nice to see the finished product.

Awesome job mate, real good :)
Do you plant to sell this ?

arkadur

very nice!!
did you plan it all? you did it on solidworks?

what about the CPU and Ram block?

Thanks!  I did it on Pro-E wildfire.  I have a CPU block in the works...

nateman_doo

ekamber

Awesome job mate, real good :)
Do you plant to sell this ?

humm.... 
ok, you talked me into it
How many would u like?

PM'ed you....cheers

would you believe I have already looked into the process of a crucible?  seems like a lot of work to do for such little in return.  Plus all the aluminum and copper get mixed up. 

Believe it or not, building the CNC machine I found MUCH easier then learning to use it!  I am pretty handy, but learning the coding involved was much harder. I am still what I consider at the "crawl" level with machining.  I have so much more to learn.
 
Glad you like it though :)

chillernr1 i'm more for 1 piece waterblock like the koolance,

The Koolance was crap, that's why they discontinued it.
 
This here is awesome work, PM sent.. I need one for my new build.

Oh man.... its gonna be a solid GPU, CPU, Mobo all in one hybrid fan/water block!!!!   lolz jk.  A solid mobo block would be interesting to see but I would worry that channel to the Vreg would choke the flow and cause to much resistance, which may have been the issue with the koolance block in the first place.  Aesthetically it works and is nice but functionally probably not so much.

Every time I come and look at this thread I can't stop staring at the block for a good minute. Now you just need to figure out how to put
nateman_doo
EVGA Classified SR-2
on top of the block so when people see it they know who made that beauty.

I ordered one last night for a new build.  I can't wait, I've always been a sucker for solid copper.  :)

loveha

Every time I come and look at this thread I can't stop staring at the block for a good minute. Now you just need to figure out how to put
nateman_doo
EVGA Classified SR-2
on top of the block so when people see it they know who made that beauty.

I have been thinking about it.  I'm not terribly creative as far as logo's go.

Where is the o-ring groove?
 
It would be nice if Nvidia/EVGA provided the step files to the public, but I don't think that will ever happen. So I guess that you will use gap pads throughout with varying thickness.