I like to call this the WCHSDP
 ~or~ 
The Water Cooled Heat Sink Documentation Project. 

GoG.Pvt.Unit

This is a before and after picture taken of the inside of my computer case. As you see the water made a huge differance

I than borrowed a micrometer from my schools drafting teacher. Micrometers can measure up to .001 of an inch (that’s 3 times SMALLER than a single strand of hair). I took these tools and measured the mounting bolts on my ASUS A78NX-Delux Mother Board. I did this several times because I didn’t want to waste resources on screw ups. Once I got the dimensions and all of the other specs I started to draft up some 2D and some 3D models.

My first and favorite design is A. but unfortunately because of the thin & deep valley we could not cut it using the milling machine. So I had to change the valley from 1/16 inch to 1/8 inch although I decided to keep the valley depth at .5 inches. Once I changed to a .125 inch bit I came up with designs B & C. as I began construction on B. I reached up to the point of creating the holes into the plastic prototype and than I realized that it was not feasible because of the size of the holes. At this point I was quite upset I had wasted 2 weeks on this idea you can see what i mean by looking at the below picture.

There was no way I could remove the water from the processor beacuse the side space was to small.

Finally I restarted my work from scratch here are some screens from my work.

At this point I began the search for some usable material. I chose copper although it is more expensive and harder to work with than aluminum it has a much higher thermal rating than aluminum.

I was looking for a nice big chunk of copper & a good thick sheet of copper. Finding the Materials was a lot harder than I originally envisioned. I searched ever where and I mean every where. Final after about 20 calls I found a place called Svinga brothers. This place had every thing from old planes, computers and scrap metal to a huge 8 ton Electric generator sitting around. The total cost of the copper was 22 bucks for the block and the sheet. I than took my treasures and ran home.

3. Program writing and building.

Before I actually cut any copper I used a wax like plastic as a blank I used this thought out the project. This way if I totally screwed up it wouldn’t matter to much.

To cut it I used my schools CNC Milling machines, which are like giant drills on the end of a robot arm. You can use the machine in 1 of two ways. You can A. control it manually or B. you can write an automated program to drill it for you. People use milling machines in manufacturing, rims, sheet metal and almost every other part of any thing you can imagine. Even computer parts can be built using CNC machines. Here are all of my programs I wrote for the machine and a picture of the modle CNC machine i used. It was a lot of work but well worth it.

4. Building the prototypes and milling the parts.

Now that I had written my programs and build virtual models I was ready to carve it out of plastic so I prepared my plastic for milling and milled away. Here are some pics of the finished milled material. Sorry I don’t have any pictures of the actual milling process. Its just I got so tied up in my work I forgot about documenting it.

Here is a picture of they copper right ontop of the wax. As you see they are the same size down to the .001 of an inch.

Here is a picture of my first wax proto but i couldn't use it beacuse of wall thickness.

Here is a pic of the proto I used at end.

And here is the block mount. (I steped on it! D:)

Now I was ready to make the finished product. No screw ups now because im cutting into my 100% pure copper.

In this one I used supper double sided tape and heat from the cutting melted the tape and the part moved off causing lota vibration and a horrible cut.

In this one I screwed up the offsets while setting them and this caused the part to be exactly 1/16 of an inch off on all sides!

I finally hit the money on this one BUT while making the wholes i again messed up. You see you have to tell the machine where the part is, so it knows where to cut. Well I told it where the part was but later i moved it out to show a friend and just put it back in with out thinking.

4th try’s the charm!

Milling the Block wasn’t so bad. I got it the first try. Milling the water path was a little harder but the first try came out almost perfect but as you see in the picture again offset problems. Milling the water path was very time consuming because of the density of the copper and the durability of the bit I had to cut the water path in .05 inch passes. Luckily I could make it automated. In the end to mill the whole thing took a total of 4 hours.

Once I completed milling both the block mount and the block. I cleaned them up and soldered them together as you see machining the part with a milling machine makes a really cool design into the surface of the copper. Although it looks wavy it is really totally flat. All that was left was threading it, spraying it with enamel and cleaning the bottom.

5. Finished product!

Bottom still needs work. looks good with threads.

Nice color and did you get a load of that beautiful solder job I did?

from a diffent view.

My god look at that Sexy (and available) man, holding that awsome heat sink. I wan't one!

6. The next step.

Well there is still the step of actually testing the heat sink. I have a good feeling about how it will perform under harsh conditions. Although there is still the task of purchasing a radiator, reservoir and pump. after that’s done all I have to do is over clock away!

Let me know what you think about the WCHSDP (but only if you have some compliment)

Cya all later and thanks for reading my gramatical & spelling error filed web page hope you gained valuable decifering knowlege.

GoG.Pvt.Unit