Log Potential case design: ~3.5-3.8L with blower GPU - 9800x3d and 4080s

[awc]

I've been thinking about a potential case design and about trying to bring it to life. After seeing this build by Jeffrey Friesen on youtube, I wanted to make my own version with a full size GPU.

That build used a Dynatron a46 1u server cooler and two rtx a2000 blower fans as the cpu cooler at only 27mm, making the total case thickness 46.1mm, when most console cases are at least 50mm+. This got me thinking, the case I have right now, a s35 from taobao, wastes a lot of space with room for a 2.5 slot card, and wastes space over the 40mm flex ATX power supply. Designing a case around this cooler and a 2 slot card could get the total volume down a lot.

I recreated the cooler design in that video and did some testing with my 9800x3d first to see if the a46 could cool my cpu with an undervolt, and while it did thermal throttle in r23, in games I saw closer to 70C using some shitty paste. With liquid metal and (maybe) a delid it should be more than enough. (I'm working on a real comparison, sorry about not having proper numbers right now)

Janky Jeffrey Friesen's a46 based cooler:

On a side note, I plan on doing a full comparison of 27-37mm coolers as I haven't seen much that is up to date. I should be getting in a id-cooling is-30i and is-37xt, and I plan on testing those vs the a46 blower design, the thermalright axp90-36, the dynatron u8, and this cooler, which is a noctua l9i heatsink with mounting brackets to rotate the fins 90 degrees.

The case I want to make uses the a46 or a simmilar cooler and has GPU spacing for a blower GPU as they are pretty standardized in sizing. I've seen blower rtx 4090 cards and so this case format should be the smallest possible rtx 4090 + 9800x3d pc, even if a blower 4090 will be super loud. I also messaged some of the taobao sellers and they seem to think a blower 5080 will eventually be a thing, so I think the build would probably use that or a 4080 super blower.

here's the layout:

the dimentions of the case would be 279 x 285.5 x 46.1mm, which is 3.67L. If I can get the thickness down to 45mm, it would be 3.58L which would make this the the smallest pc with these specs by a lot.

I have access to very cheap aluminum stock and CNC machines at my college so this will hopefully become a case. If a CNCed case doesn't work out I am thinking sheet metal could also work, although I think that would increase the size by a bit.

What do you guys think? I haven't designed a case before but I haven't seen anything else like this and would love to shave 1.5L off my PC, lol.

 

[awc]

also, I would kill for any of the models in that Jeffrey Friesen video, if they exist anywhere on this site lol

 

[awc]

Figured I should prob update this: my models are mostly done, and I've got a few 3d printed test versions. I found a 4080 super that is 248mm long and 110mm tall, and I took apart the flex atx psu to get the height down from 40.5mm to around 38mm, which combined should get the size down to 3.0L. Hopefully I can get my hands on the 4080 super, and if I can the final build should be 254x280x42.5 or 3.02L. Really want to get it to 2.99L but I def need the GPU to see if thats possible. I've also looked into geting a custom vapor chamber cpu heatsink made that covers a delided 9800x3d and the motherboard VRM, but that will be 300-500$ if I only buy one so IDK if that will happen, lol. I've also been thinking about finding a 5080 with a very small PCB and then designing a blower heatsink for it, but thats just a thought right now. Also just finished shortening all the cables on my flex PSU and rounting them but havent tested it yet.

here are some pics and renders: (renders are of an older version for the 267mm blower card, the printed version is for the 248mm card)

 

[awc]

oh, also I found a gen 5 pcie riser that is the exact right size to fit a 2 slot gpu and keep the total width 1u. its the Supermicro RSC-S-6G5 if anyone wants to make a 1u case like this, I had a really hard time finding any others that fit a 2 slot card but aren't too tall, but this one is perfect

 

[Hungrythundr]

I working on something similar but with an external PSU and a large 100mm blower fan for the CPU .

 

[dc443]

Could you evaluate the volume for a 5090FE? Under 5L possible?

because the flow through should be viable given your layout. I think an expensive flex psu can be up to the task.

 

[awc]

Could you evaluate the volume for a 5090FE? Under 5L possible?

because the flow through should be viable given your layout. I think an expensive flex psu can be up to the task.

4L is probably possible with a 5090FE and this CPU cooler. Shrinking the CPU cooler to 27mm and making to total case around 45mm saves a LOT of volume.

 

[awc]

I decided to switch the case to use a inno3d 5080 with a cooler swap when I saw the inno3d X2 5070 had a very similar PCB to the 5080. Gonna try a cooler swap with the x2 cooler on the 5080. Will get both cards on the 8th and I'll update here with the cooler swap.

Current design is 42*253.5*281.75mm making it 2.999L (lol). However I might need to add a few mm depending on the 5080 cooler swap size as I don't have it yet. Sub 3L would be crazy but it probably won't happen. I'm thinking 3.0L is possible though, if this cooler swap works

 

[awc]

Just got the inno3d 5070 and 5080. Haven't tried the cooler swap but with some slight modification (and a soldered 12vhpwr connector) the 5070 x2 fits it the sub 3L case, so if the cooler swap works then sub 3L with a 9800x3d and 5080 is possible! Will post pics when I finish the swap

 

[rfarmer]

Just got the inno3d 5070 and 5080. Haven't tried the cooler swap but with some slight modification (and a soldered 12vhpwr connector) the 5070 x2 fits it the sub 3L case, so if the cooler swap works then sub 3L with a 9800x3d and 5080 is possible! Will post pics when I finish the swap

Cool I look forward to seeing this. I have the Inno3d 5080 X3 OC, I'm guessing you have the non OC model?

 

[awc]

Cool I look forward to seeing this. I have the Inno3d 5080 X3 OC, I'm guessing you have the non OC model?

I got the OC model yeah. Mounting is the same so might as well.

Cooler swap was a breeze! All the mounting holes and pads match up perfectly. Literally everything matches up perfectly, the only issue is the longer board length of the 5080. So I had to spend a few hours with a Dremel shaving down 8 of the fins to make room for it.

Currently have the 5080 running with the 5070 cooler. I haven't done any stress testing because I need to finish the case before I can really test the cooler bc, I gotta figure out mounting with the 4070fe fans I'm using) but here are some pics so far. I pan on doing a write up at some point tho lol

Here are all the pics I took, not organized or anything:

 

[rfarmer]

That's very cool. Did you undervolt at all? I have mine drawing about 275W with an undervolt.

 

[awc]

That's very cool. Did you undervolt at all? I have mine drawing about 275W with an undervolt.

Haven't done any testing yet but will do a noise and temp comparison of the 5080 and 4080 super

 

[awc]

I've done a lot since I last posted here. After (too many) tweaks to the case design and a lot of FDM prints, I've mostly finished the case design. I had a bunch of issues with the 5080 not working with my 9800x3d but working with my older 5800x3d build. turned out the 5080 wouldn't boot through DP but would through HDMI, only when paired with the 9800x3d.

I just finished replacing the 12VHPWR on my 5080 with a soldered XT60 connector, and I got boot with the soldered connector on the GPU. I am planning on getting a polished SLM aluminum version printed in the next few days through PCBway. I really did NOT think I would get boot with my soldered 5080 but I guess it works!

Final volume is 2.99L, 9800x3d, rtx 5080. really hyped to get the aluminum version, I really thought sub 3L with this hardware would not be possible.

Here are some pics:

 

[Curiosity]

This is extremely cool, I love the soldered power input.
Getting under 3l is amazing, that dual blower through a 1u cooler design by Jeffrey Friesen was a really good technique!

 

[awc]

I got the metal SLM version of the case! Shipped it to Canada and took it across the boarder to avoid tariffs lol. It came out very good, there is some slight distortion with the backside not being perfectly flat, but the surface finish is great. You can see the normal textured surface finish from SLM printing inside the case and the brushed look from pcbway on the outside. Took some slight post processing to get the GPU to fit but it is it! I should have it running by tomorrow or the weekend once I get some kapton tape. Here are pics:

 

[Curiosity]

That's so sick.
What did it cost for the part alone? I have no metric for what parts like these cost.

 

[awc]

That's so sick.
What did it cost for the part alone? I have no metric for what parts like these cost.

the cpu heatsink is around 50$ from dynatron, and the a2000 fans were like 20$ per fan, (although prob cheaper from china) and then maybe like 10$ to make an adapter to connect the fans to the mobo, and the fan shroud was free because I can 3d print for free.

the 5080 was 1200$ from taobao and the 5070 was 600$. I sold the 5070 with the 5080 cooler on it for 400$ to a friend although I imagine I could have gotten 500. I bought 4070 FE fans for the 5080 for like 10-15 for each, and then there was small parts for getting the fans connected to the mobo and the power connector for the gpu.

the case was $700 from PCBway, although I asked them to sand and brush the outer surfaces which probably added 150-250$. I wouldn't have them do this if i did it again because I still have to do post processing after getting the case due to printing distortion (which I was warned about)

I ordered the Case to canada and bought the GPUs before the tariffs. If I had shipped to the US, the case would have been $500 more and the GPUs would probably be close to $1000 more.

I looked into a custom CPU heatsink with a vapor chamber. If I removed the motherboard VRM heatsink and used the CPU heatsink for the VRM, it could be about 30% larger and use a 3rd a2000 fan. also, I could delid the CPU which is currently not possible with this heatsink. I was quoted between $400-$850 IIRC for the full cooler if I only ordered only one, or "significantly less" if I ordered multiple as I was told setting up the tooling was the main cost. I was also thinking about buying a custom vapor chamber and then soldering on the fins myself, which would have been a few hundred less. I decided this wasn't worth it considering the cooler I have is adaquate for the undervolt I am running and that my CPU is usually not fully used in games, however I might reconsider in the future if I upgrade CPUs and cooling is an issue.

Last thing I am thinking about doing is a RAM heatsink to connect to the metal side panel. I'm thinking this will be like 20-60$ depending on how I do it.

everything else is off the shelf parts so normal pricing. Sorry if this is more than what you wanted lol

 

[Curiosity]

I'm happy for more detail
And I do appreciate it, really cool info to hear
'$550' seems wild but it makes sense due to the sheer volume of material needed and how much space it takes up on their devices. Sorry to hear the brushing wasn't worth it, I don't blame you for being optimistic though.

A ramsink is always sweet imo, even if it may not be necessary. but with a unibody chassis you may as well take advantage of it!

 

[S4YIND]

Please tell me how much maximum W can it withstand at maximum cooler speeds? I want to insert a ryzen 9 9950x with a 180W TDP into such a configuration.