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Helpful ReplyHot!*NEW* 100% Copper SR2 full coverage waterblock

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nateman_doo
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2011/04/03 15:58:58 (permalink)
Full Copper SR2 waterblock
(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:







 
post edited by nateman_doo - 2015/07/02 09:34:39
#1
_MatthewH
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Re:100% Copper SR2 full coverage waterblock! 2011/04/03 16:20:16 (permalink)
Looks great.

Thanks,
Matthew Hurwitz - Assistant Product Manager Matth@evga.com 
Feel free to contact us with any questions, comments or concerns: Toll Free 888-881-3842 
You can rate our service here: http://www.evga.com/myevga/rateus/

#2
VistaHead
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Re:100% Copper SR2 full coverage waterblock! 2011/04/03 16:32:34 (permalink)
That looks really good!!  What is it sealed with, Permatex?
#3
bomberboysk
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Re:100% Copper SR2 full coverage waterblock! 2011/04/03 18:38:33 (permalink)
Nate, that looks awesome

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#4
nateman_doo
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Re:100% Copper SR2 full coverage waterblock! 2011/04/03 18:53:07 (permalink)
VistaHead

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

Thanks!  yes, I designed this one for Permatex. 

#5
DraginElite
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Re:100% Copper SR2 full coverage waterblock! 2011/04/03 22:35:30 (permalink)
looks real good ND
#6
kaninja
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Re:100% Copper SR2 full coverage waterblock! 2011/04/03 23:03:09 (permalink)
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.

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#7
arkadur
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 01:00:34 (permalink)
very nice!!
did you plan it all? you did it on solidworks?
 
what about the CPU and Ram block?
#8
ekamber
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 04:09:12 (permalink)
Awesome job mate, real good :)
Do you plant to sell this ?
#9
nikkocortez
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 04:58:43 (permalink) ☄ Helpful
I'm sure he plans to sell them. 
post edited by nikkocortez - 2011/04/04 05:05:57
#10
nateman_doo
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 05:14:34 (permalink)
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...
#11
nateman_doo
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 05:15:47 (permalink)
ekamber

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

humm.... 
ok, you talked me into it
How many would u like?
#12
ekamber
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 06:50:40 (permalink)
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
#13
Halo_003
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 08:32:21 (permalink)
Looks great! What do you do with the chips and bits of copper left over from milling? Melt them down and start again? 

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#14
nateman_doo
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 08:39:53 (permalink)
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. 
#15
stillborn07
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 12:39:28 (permalink)
Wow truly awesome work.  But I have to be honest, after "...I built a CNC machine from scratch"...everything else was just bonus.  haha

 
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#16
nateman_doo
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Re:100% Copper SR2 full coverage waterblock! 2011/04/04 13:38:07 (permalink)
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 :)
#17
chillernr1
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Re:100% Copper SR2 full coverage waterblock! 2011/04/10 14:31:05 (permalink)
i'm more for 1 piece waterblock like the koolance,
 
to bad you didn't choose to make like that.
#18
Tobit
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Re:100% Copper SR2 full coverage waterblock! 2011/04/10 15:00:50 (permalink)
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.

 
#19
nateman_doo
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Re:100% Copper SR2 full coverage waterblock! 2011/04/10 17:44:33 (permalink)
chillernr1

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

to bad you didn't choose to make like that.

The problem with that, is the size of copper required to do it.  If I made it, it would be truly 1 piece.  I would route out all sorts of channels around this and that.  The problem with making one, is the size of the copper sheet required.  Sheets of copper come in nice whole amounts like 12x12, 12x24 etc.  So I would need a ghastly large hulking sheet of copper to make a top and bottom.
 
If you wish to employ me efforts I will be happy to accommodate. 
#20
nikkocortez
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Re:100% Copper SR2 full coverage waterblock! 2011/04/10 19:32:42 (permalink)
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.
#21
Halfdead14
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 00:04:10 (permalink)
Looks great, now show us how you built the cnc machine :P
#22
loveha
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 01:40:38 (permalink)
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.


#23
EVGATech_MattM
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 02:24:55 (permalink)
Looks great.  I kind of want to build a CNC machine but I don't know what I would build with it.  I guess you build it then the reasons to have it appear.
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Tobit
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 04:39:04 (permalink)
I ordered one last night for a new build.  I can't wait, I've always been a sucker for solid copper.  :)

 
#25
nikkocortez
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 05:17:16 (permalink) ☄ Helpful
They are nice.  I have one sitting on my desk currently.   Now I'm just waiting to get the rest of my parts for my loop. 

 
In fact I believe the pics up top are of the block I have being made.  Its outstanding work and well worth it. 
post edited by nikkocortez - 2011/04/11 05:20:24
#26
nateman_doo
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 05:18:17 (permalink)
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.
#27
nateman_doo
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 05:24:30 (permalink)
Halfdead14

Looks great, now show us how you built the cnc machine :P

That is going to be its own post when I get around to it :)
#28
vincinator44
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 05:50:58 (permalink)
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.
#29
loveha
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Re:100% Copper SR2 full coverage waterblock! 2011/04/11 06:16:13 (permalink)
vincinator44

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.


nateman_doo

VistaHead

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

Thanks!  yes, I designed this one for Permatex. 


Is there is no O-Ring. Sealed by the method above.


#30
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