EDIT: This project is done.  Final pics are here.
 
 
I've been commissioned to build an external radiator case which is destined to sit on the top of an 800D.  The case will be made entirely from aluminum and built to house two triple radiators.

Here's a drawing of the case:



The frame of the case is made from 1-inch channel, 1/2 x 3/4-inch and 3/8 x 3/4 flat bar.




The corner blocks were made from 3/8 x 3/4 flat bar:




The alignment of all three corner pieces turned out to be spot-on:




The frame is fastened together with self tapping stainless screws.







 
I cut out the bottom, top and sides of the case with my hand held router, guided by a straight edge.



The entire bottom of the case is perforated aluminum so as not to impede the exhaust from the 800D, eventually standing on some nice beefy mnpctech case feet. 






 
Side panels bolted on with stainless steel socket cap flat head bolts.






Up on mnpctech case feet:




 

Wow, that is 1 strong box!
 
I intend to do similar. I want an external rad/pump/res setup. 
I plan to make an insulated box for it all

nickbaldwin86
Wow very nice job to this point.
you going to mount it to the case? top? bottom? or have quick disconnects?

Thanks.  The case is going to rest on top of the 800D (that's why the bottom of the case is perforated aluminum).   There will be four disconnects on the back.

bucyrus5000
Wow, that is 1 strong box!
I intend to do similar. I want an external rad/pump/res setup. 
I plan to make an insulated box for it all

Thanks,

4 disconnects? So 2 loops? 
 
 
If you have a res in the box, it can't go under the rig, or am I wrong? If it is on the bottom it will leak at the res when someone goes to fill or drain it. Unless there are a 1-way valve, but even then you need to pressurize the res to force the new fluid in.

Nice once again Spotswood!!! Was looking to do the same with acrylic....of course

wcchamp18
LMAO! It just now hit me! "Spotswood"! LOL, sorry no offense meant!

  No offense taken.  Its the name of my hometown.

These seem to be all the RAGE now huh?
 
I keep seeing them pop up one after another!

Looking good!  You seem to do so well with whatever medium you work with.   Keep up the good work and I'll be taking notes. 

Good work Cannot wait to see your finished product...
 
P.S...

amazing work, didnt know there were any custom case builders up in NE :) glad to know there are :)

notfordman

Great project! Those corner braces aren't gonna move. You are making some nice straight cuts. You did say you were using a router,right? What kinda bit are you going with? Keep us updated with progress.

 
I used plain-old carbide woodworking bits: two passes, the first with a slightly overhanging patten bit, followed by a flush pattern bit.
 
I finally got the perforated sheets attached to the side panels.







 

Spotswood
I used plain-old carbide woodworking bits: two passes, the first with a slightly overhanging patten bit, followed by a flush pattern bit.

 
Wait, you use a carbide wood router bit in cutting the metal?

Spotswood

Um, yeah.  Don't you? 

 
No.  Actually I've hardly ever worked with metal.  You seem to be good with any medium you work with!  It is nice to know about the bits though.  I'm learning something new everyday!  Thanks for the help.

This looks great. Keep it up 

Very nice work. Keep it up! I am really looking forward to the finished product.  I wish I had the time, patience and skills to do something like this.