Posted in several other places on the forums asking for advice/feedback on a potential build, and after many iterations in CAD I'm confident enough in the design that I've decided to go ahead with it, even if there's the possibility of a couple things not working out perfectly!
Ever since I bought the v3 A4 in 2018 I've been intrigued by the idea of doing a full custom loop (ie CPU+GPU), but at the time I didn't see how it could be done, since the case was designed for CPU AIO but had no such considerations the GPU. So I built a bog standard air cooled rig and was happy with it until this year, when something possessed me to check back in on the SFF community to see what was new.
Lo and behold I came across several loops that others had built in the inaugural Dan case, one with a 120mm and 92mm rads, another with two dual-40mm rads, and another one that dropped in a 240mm rad in place of the GPU. All unique and creative solutions, but there were a number of things that bugged me - hacking up the case, tube routing that caused panel bulging or ran outside the case, and just a general DIY look that aren't quite as appealing as the HoF builds - although most if not all of those can attribute their good looks to having their rads (and even pumps) outside of the case which...is not something I would want to do, I want all my PC components...inside my PC (with one unfortunate exception, later on).
With those examples in mind I set a number of goals for myself as I revisit doing my own custom loop:
In virtual prototyping, the biggest challenge became where to put 240mm of radiators. The A4 is designed to hold a single slim-ish 120mm AIO at most. This is where I spent the most time, coming up with various radiator and fan combinations that would give me the most surface area and airflow. I eventually settled on this:
That's two Alphacool HPE ST20's paired with Noctua A12's set to exhaust, attached to the OEM AIO brackets on each side. Then at the top and the bottom, are two A9's set as intakes to feed the A12's. This is the part of the design I'm least sure about, as there's only about ~1.3cm between the two A12's, and I'm not sure how badly they'll interfere with each other. If this (6th image) was able to achieve reasonable temps, I am hoping mine will too.
This arrangement required the PSU to be relocated, and the only space available for it is under the GPU (blue thing bottom-left, GPU above and radiator on right):
I really, really wanted to use one of HDPLEX's new GaN power supplies, however neither the existing models would fit so I have to rely on the 500w Ac/Dc and get an external brick (this is the big compromise I mentioned earlier). The Ac/Dc model though fits perfectly under the GPU, helping to achieve that OEM look - all the pinouts align with the space under the motherboard, so the power cables can be routed underneath the same way the PCIe riser cable is. I'll have to shorten all the cables though, as they are ridiculously long for where they need to go.
Another issue with putting the PSU in that space is there is little to no airflow, and while it is supposed to be a passively cooled PSU I'm sure it would appreciate getting some air. To address that, I plan on removing the panels on the short sides of the heatsink and putting A4's on either side to create a wind tunnel that will pull air from the front with the A9's and A12's and exhaust out through the hole originally designed for the power cable.
The last bit of the puzzle was...where the heck do I route the plumbing? The sandwich-style case doesn't have many openings for tubes to run from one side to the other, so it took a lot of minute adjustments and research on fittings before I eventually settled on this:
...I don't know if those images makes any sense, but it's CPU > GPU > RAD > RAD > CPU using 12mmOD hard tubing. The only way to get it to work on the GPU side is to use the micro push-in fittings, as the standard compression fittings are too large. In terms of filling, there's the G1/8 port on the ModUltra and I plan on putting one of those EKWB cylindrical T fittings on the CPU side, so I can place the case on its side, GPU-side down, and open both of those up to fill and exhaust air.
...and that's it, currently. About a month of planning and iterating in the digital space, and now time to make it real! I got all the main components and am going to do a dry run outside the case tomorrow to make sure i didn't get any dud parts, and if all goes well the remaining water cooling components will follow and hopefully get it all crammed in there without much ado.
Many photos of the <1mm clearances I anticipate (and have experienced so far) to follow.
Ever since I bought the v3 A4 in 2018 I've been intrigued by the idea of doing a full custom loop (ie CPU+GPU), but at the time I didn't see how it could be done, since the case was designed for CPU AIO but had no such considerations the GPU. So I built a bog standard air cooled rig and was happy with it until this year, when something possessed me to check back in on the SFF community to see what was new.
Lo and behold I came across several loops that others had built in the inaugural Dan case, one with a 120mm and 92mm rads, another with two dual-40mm rads, and another one that dropped in a 240mm rad in place of the GPU. All unique and creative solutions, but there were a number of things that bugged me - hacking up the case, tube routing that caused panel bulging or ran outside the case, and just a general DIY look that aren't quite as appealing as the HoF builds - although most if not all of those can attribute their good looks to having their rads (and even pumps) outside of the case which...is not something I would want to do, I want all my PC components...inside my PC (with one unfortunate exception, later on).
With those examples in mind I set a number of goals for myself as I revisit doing my own custom loop:
- Full loop including the CPU and GPU that is housed completely within the case.
- Get the minimum amount of radiator surface area recommended for two components - 240mm.
- Look like an OEM assembly - every part should look as if it was designed to go where it is.
- Better temperature performance/noise than my current build (otherwise what's the point?)
In virtual prototyping, the biggest challenge became where to put 240mm of radiators. The A4 is designed to hold a single slim-ish 120mm AIO at most. This is where I spent the most time, coming up with various radiator and fan combinations that would give me the most surface area and airflow. I eventually settled on this:
That's two Alphacool HPE ST20's paired with Noctua A12's set to exhaust, attached to the OEM AIO brackets on each side. Then at the top and the bottom, are two A9's set as intakes to feed the A12's. This is the part of the design I'm least sure about, as there's only about ~1.3cm between the two A12's, and I'm not sure how badly they'll interfere with each other. If this (6th image) was able to achieve reasonable temps, I am hoping mine will too.
This arrangement required the PSU to be relocated, and the only space available for it is under the GPU (blue thing bottom-left, GPU above and radiator on right):
I really, really wanted to use one of HDPLEX's new GaN power supplies, however neither the existing models would fit so I have to rely on the 500w Ac/Dc and get an external brick (this is the big compromise I mentioned earlier). The Ac/Dc model though fits perfectly under the GPU, helping to achieve that OEM look - all the pinouts align with the space under the motherboard, so the power cables can be routed underneath the same way the PCIe riser cable is. I'll have to shorten all the cables though, as they are ridiculously long for where they need to go.
Another issue with putting the PSU in that space is there is little to no airflow, and while it is supposed to be a passively cooled PSU I'm sure it would appreciate getting some air. To address that, I plan on removing the panels on the short sides of the heatsink and putting A4's on either side to create a wind tunnel that will pull air from the front with the A9's and A12's and exhaust out through the hole originally designed for the power cable.
The last bit of the puzzle was...where the heck do I route the plumbing? The sandwich-style case doesn't have many openings for tubes to run from one side to the other, so it took a lot of minute adjustments and research on fittings before I eventually settled on this:
...I don't know if those images makes any sense, but it's CPU > GPU > RAD > RAD > CPU using 12mmOD hard tubing. The only way to get it to work on the GPU side is to use the micro push-in fittings, as the standard compression fittings are too large. In terms of filling, there's the G1/8 port on the ModUltra and I plan on putting one of those EKWB cylindrical T fittings on the CPU side, so I can place the case on its side, GPU-side down, and open both of those up to fill and exhaust air.
...and that's it, currently. About a month of planning and iterating in the digital space, and now time to make it real! I got all the main components and am going to do a dry run outside the case tomorrow to make sure i didn't get any dud parts, and if all goes well the remaining water cooling components will follow and hopefully get it all crammed in there without much ado.
Many photos of the <1mm clearances I anticipate (and have experienced so far) to follow.
