Fred - Part 1 - Modding The Quiet Into A Server Rack Case Entry created on 2020-11-22 (edited 2022-08-20) author:steeph (365) cat:Case Modding (11) cat:Computer (77) cat:DIY (15) cat:Fred (3) cat:Hardware (16) cat:Hoarding (5) cat:Projects (40) lang:en (251) top:Projects:Case Modding:Fred (3)

Fred is an old Supermicro rack server that I got as an attempt at building a NAS that replaces all the smaller NASs that I already had. But I like to collect stuff and it's never going to be enough. So it ended up being just another extension of my home network.

Overview

It's an old 3U Supermicro server case with 16 3.5" hard drive drawers, a good but not too bulky Asus motherboard and a nice low-power Intel CPU. I kept the motherboard, CPU and 32 GB ECC RAM. It's more than enough.

I wanted to do some mods on the case though to make it more comparible to my home and my visual taste in computer cases. In short, what I did was: Switch the PSU to a quieter one, build fans into the lid for quieter drive and card cooling, painted the case, switched the CPU cooler for passive cooling, added two HBA cards and 14 8 TB hard drives (two drawers left intentionally free).

I will tell about/may document these mods in more detail in separate entries.

File Attachments (22 files)
The case before I started (but not before I added some stickers)
The case before I started (but not before I added some stickers)
The pretty much finished case
The pretty much finished case
Fred-3-IMG_20200516_203621.jpg (image/jpeg, 2372090 B)
Fred-3-IMG_20200516_203621.jpg (image/jpeg, 2372090 B)
Fred-3-IMG_20200516_203634.jpg (image/jpeg, 2341046 B)
Fred-3-IMG_20200516_203634.jpg (image/jpeg, 2341046 B)
Fred-4-IMG_20200516_203641.jpg (image/jpeg, 2899272 B)
Fred-4-IMG_20200516_203641.jpg (image/jpeg, 2899272 B)
Making the holes for the fans was easier than I expected. I marked the borders with a pencil by following the outlines of the actual fans, cut the rough holes with an angle grinder with a cutting disk, then did the finishing with a rotary tool (a not Dremel).
Making the holes for the fans was easier than I expected. I marked the borders with a pencil by following the outlines of the actual fans, cut the rough holes with an angle grinder with a cutting disk, then did the finishing with a rotary tool (a not Dremel).
I used up several cheap grinding bits for the finishing. The remaining borders between the fas are only a few millimeters wide. But the ~2 mm thick steel holds up surprisingly well. They don't make regular home computer cases from that material.
I used up several cheap grinding bits for the finishing. The remaining borders between the fas are only a few millimeters wide. But the ~2 mm thick steel holds up surprisingly well. They don't make regular home computer cases from that material.
First coat: primer, second coat: matte black, thirdly added sparkly sprinkles. In the picture I started taping the sides for what comes next.
First coat: primer, second coat: matte black, thirdly added sparkly sprinkles. In the picture I started taping the sides for what comes next.
Then I painted the middle part pink. After the tape was removed I noticed the paint came off in one spot. Well, that's how it goes if you don't do it right. I can just cover this with a sticker. For now I just added a matte clearcoat.
Then I painted the middle part pink. After the tape was removed I noticed the paint came off in one spot. Well, that's how it goes if you don't do it right. I can just cover this with a sticker. For now I just added a matte clearcoat.
In between cooling systems. I tested the modded lid as it was in the picture but closed. It did do something and it was better than the open case with scattered fans in the next picture, but not by much.
In between cooling systems. I tested the modded lid as it was in the picture but closed. It did do something and it was better than the open case with scattered fans in the next picture, but not by much.
That's how it looked for a day while I used the NAS before finishing the new cooling system. Notice the large space in the middle. That will be used in the next pictures.
That's how it looked for a day while I used the NAS before finishing the new cooling system. Notice the large space in the middle. That will be used in the next pictures.
This is how the case looked inside now. (I'll write about the power supply in the next entry.)
This is how the case looked inside now. (I'll write about the power supply in the next entry.)
Fred_Case_Lid-08-IMG_20200502_082859.jpg (image/jpeg, 2401167 B)
Fred_Case_Lid-08-IMG_20200502_082859.jpg (image/jpeg, 2401167 B)
And from the outside. The fan on the bottom right cools the RAID card and the HBA. I don't know if it's cooling it enough because I don't know what the cards/processors are made to withstand. But they still ran a few years after that picture was taken. The CPU fan is off because it stays cool enough during a hours-long burn test.
And from the outside. The fan on the bottom right cools the RAID card and the HBA. I don't know if it's cooling it enough because I don't know what the cards/processors are made to withstand. But they still ran a few years after that picture was taken. The CPU fan is off because it stays cool enough during a hours-long burn test.
The cooler mount wasn't made for that socket. I think it was for an AMD socket. The bracket was really strong and tight and eventually broke in two. The CPU lid didn't take any damage though and I simply used a few zipties to hold the cooler in place without much preasure on the CPU. That still was enough to cool the CPU passively and the machine ran three quarters of a year that way.
The cooler mount wasn't made for that socket. I think it was for an AMD socket. The bracket was really strong and tight and eventually broke in two. The CPU lid didn't take any damage though and I simply used a few zipties to hold the cooler in place without much preasure on the CPU. That still was enough to cool the CPU passively and the machine ran three quarters of a year that way.
Fred_Case_Lid-11-PXL_20210424_093519403.jpg (image/jpeg, 3628307 B)
Fred_Case_Lid-11-PXL_20210424_093519403.jpg (image/jpeg, 3628307 B)
Eventually I made my own bracket (not in the picture) and now that is held down by zipties. It's quite sturdy.
Eventually I made my own bracket (not in the picture) and now that is held down by zipties. It's quite sturdy.
The old power supply after it died. (The unplugged fan and the missing screws do not resemble how it looked while it was in use.)
The old power supply after it died. (The unplugged fan and the missing screws do not resemble how it looked while it was in use.)
Maybe it would have lived longer if I had cooled it better. It wasn't efficient. It would have been too loud.
Maybe it would have lived longer if I had cooled it better. It wasn't efficient. It would have been too loud.
The new power supply. Fits well in height and leaves more than enough room for its modular cables (even for the ones that aren't used) and airflow.
The new power supply. Fits well in height and leaves more than enough room for its modular cables (even for the ones that aren't used) and airflow.
I'm happy with the adapter plate and how it turned out, even though I originally made it for a different SFX unit and the fan cutout now seems redundant. But it actually looks kind of professional. That's rare enough with me. I bet you can't tell which part I made myself. (Or is this because the photo is so bad?)
I'm happy with the adapter plate and how it turned out, even though I originally made it for a different SFX unit and the fan cutout now seems redundant. But it actually looks kind of professional. That's rare enough with me. I bet you can't tell which part I made myself. (Or is this because the photo is so bad?)
I made my own modular cables with old molex connectors for the HDD backplane. The unused cables in the plastic bag has its place at the back of the PSU.
I made my own modular cables with old molex connectors for the HDD backplane. The unused cables in the plastic bag has its place at the back of the PSU.
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