Concept Yet another 10L watercooled mini-ITX

Which of these designs would you prefer to buy/use? (with/without changes, please comment in thread)

  • Cons(f)ol(d)e as-is, looks great

    Votes: 0 0.0%
  • Cons(f)ol(d)e, but it needs work

    Votes: 0 0.0%
  • Thinny-ITX, but it needs work

    Votes: 0 0.0%

  • Total voters
    2

SFFMunkee

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Jul 7, 2021
21
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Hi everyone,

I'm developing a case primarily for my own personal use, but potentially production version if enough interest too.

I have discovered that most, if not all, of the cases I've been looking at with 240mm rad support only support either slim rads or fans or both, although some do support 2 radiators, and I'm I'm not convinced a single slim 240mm will provide sufficient cooling performance, so I'll keep my Alphacool XT45 and Silverstone Air Blazer fans.

I'm going to design a case that will house ITX motherboard supporting high-end CPU and GPU with custom watercooling for both being an expectation at this stage. However it must be of a reasonably small size, NR200 exists but is around 18L so I'm aiming for 12L and below (8L is probably a hard minimum for standard SFX PSU and 240mm rad).

To achieve this size, I'd need to move to a pump/res integrated CPU block, currently the contenders are:
Alphacool
Both Alphacool units use the DC-LT-2 pump ( 4W, 7 - 13.5 V DC (non-PWM), 2600 rpm, 75 L/h, 0.95m head)
- Eisbaer (Solo) [https://www.alphacool.com/shop/cpu-.../alphacool-eisbaer-solo-2600rpm-black?c=23741] approx 68mm tall + fittings
- Eisbaer LT (Solo) [https://www.alphacool.com/shop/cpu-water-cooler/amd/am4-ryzen/23937/alphacool-eisbaer-lt-solo-black] approx 39mm tall with horizontal fittings

Nouvolo
Nouvolo units come without a pump, but support DDC design.
Likely end up with EK DDC 4.2 PWM pump ( 18W @ 12 V DC, 4x00 rpm?, 1000 L/h, 5.2m head), approx 60mm tall (+ fittings) with pump installed
- Nouvolo Aquanaut Combo [https://www.nouvolo.com/pages/aquanaut#aq-combo]
- Nouvolo Aquanaut Extreme [https://www.nouvolo.com/pages/aquanaut#aq-extreme]

Barrow
- Barrow LTPRKA-04 Pump/Block/Res combo - approx 64mm tall + fittings [http://www.barrowint.com/product/cpuslt/Barrow_cpu_water_block/1604.html]
Uses Barrow's DDC clone pump (specs?)

Looking at the current mock-up, I'd have <73mm total height from socket to radiator which is definitely going to be tight but doable, the Alphacool LT gives an extra bit of space and has side fittings so could probably mount an additional 25mm.
Alternate desktop 'console style' version too:
upload_2021-10-7_3-51-48.png

upload_2021-10-7_3-53-8.png

Currently debating whether to do a vertical tower, or a thin 'console' style case.
I have 3 semi-considered designs I'm mulling over:
1) The Cons(f)ol(d)e: 10.8L (can be reduced if dropping spare x8 PCIe slot)


2) The Zen of Chonk: 9.4L vertical orientation with IO underneath


3) Thinny-ITX: 12L with 2 PCIe x8 slots and space to spare in plenty of spots.
22 Oct 2021 Update:
I've been working on two different versions of the vertical tower 'zen of chonk'

One (ZenChonk L) with greater capacity for fat (but not ultra-long) GPUs and dual 240mm radiators. This would bring the volume up to 12.2L, and requires a PCIe riser, but it significantly expands compatibility and ease of installation, the other (ZenChonk S) with the smaller volume but only capable of taking the single radiator & single-slot W/C GPU.

I've also been working on the mechanical attachment of panels, while keeping to mostly individual pieces for flat-pack shipping options. Haven't decided whether or not to keep the tri-fold cover plate (like the AT computers of old!) or move to separate side/top panels.

ZEN CHONK L
Dimensions as shown:
Width 154.2 mm
Height 312.2 mm (exc 15mm feet)
Depth 253.6 mm
Volume = 12.21 L (plus feet)






ZEN CHONK S
If I want to keep the volume/dimensions as small as possible, and restrict to single-slot, ~280mm GPU, and single 240x45mm radiator then I can get it down to approx 9.3L:

Dimensions as shown:
Width 162 mm
Height 297.9 mm (exc 15mm feet)
Depth 192.4 mm
Volume = 9.3 L (plus feet)




Test Setup
I set up a roughly-equivalent, but open, layout to the ZenChonk S (although I accidentally placed the rad the wrong way around so the PSU can't currently fit behind the rad where it should) and tested it. The tubing you can see off the EK 45deg fitting is a makeshift reservoir. This allowed me to bleed the air out, after which I drained the res-tube and fitting, and capped off at the T-fitting.

You can see the Corsair SFX PSU behind Grumpy Bear's head, the rad is sitting atop the backplated GPU and the motherboard is slid onto the GPU via the PCIe slot. Thin foam sits underneath the GPU and between the rad/GPU which keeps things relatively stable. I wouldn't want to leave it like this permanently, but it's secure enough that I could (carefully) pick up the whole rig and turn/shake it to help bleed out the remaining air.



Thermal Testing
I have determined that the single-loop with Eisbaer LT & 240mm XT45 is sufficient to cool CPU & GPU if not heavily overclocking. A 1-hour OCCT run had both peaking around 80C with about 115W + 292W according to HWInfo64.

At regular usage it's completely inaudible, and even when pushing hard it's not an obnoxious sound profile, thanks to the 2x120mm Air Blazers which are surprisingly tolerable sounding fans even at 100% rpm.

Will do some further thermal/noise tests later, and continue with planning the case design(s).

Design Files
For Sketchup (.skp) files see my 3rd post here
 
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SFFMunkee

Caliper Novice
Original poster
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Jul 7, 2021
21
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Looks like it's time for me to start learning Fusion360 so I can make manufacturable parts. Had a quick crack at it today but it looks like it's a bit of a learning curve coming from Sketchup. This means it'll be a while before I have enough skill to reproduce something representative, as I don't have much in the way of free time to learn. Fingers crossed for a first draft F360 design this month!

Archived content:

Hi everyone,

TL;DR: I turned my A4-SFX on it's end, now I need to fit a bigger GPU and make it less ugly.

:: WAFFLE ::
I've been building SFF machines for years, usually a hodge-podge of DIY and some form of miniature parts (PicoPSU, early VIA-based ITX boards, DIY heatpipe passive cooling etc.) then a plethora of different ITX retail cases but none of them were every QUITE right.

Along came the DAN A4-SFX, and it was love at first sight, but unfortunately it wasn't available to purchase. After months of watching, polls, prototypes, redesigns, the Kickstarter was released and AU$456 later I was the proud owner of a place in line for the case.

Another waiting game until, finally, March 2017 arrives along with my A4-SFX v1 (#574 of the original 950 expected to be produced).
20170307_073830593_iOS.jpg
Size comparison between: Rosewill Legacy W1B (~31L), Silverstone RVZ01 (~14L) and DAN A4-SFX (~7.2L)

Original build (March 2017)
  • Asus Z97I Plus mITX
  • Intel Core i5 4570 + Cryorig C7
  • 2x8GB Corsair Vengeance LPX
  • Asus GTX 970 Strix -> (April 2017) Gigabyte GTX1080 Founders Edition
  • 1TB Samsung 840 SATA SSD + 2TB Seagate SATA HDD
  • Silverstone SX500-LG 500W with flat/ITX cables
20170307_090520161_iOS.jpg
Mmm Haswell build with shitty NVMe boot support

My PC sat in basically this state until recently, when I was messing around with some Apple VMs and needed AMD cards, did some switcheroos and ended up with a 5700XT instead and a couple of older AMD cards in the VM box, eventually they were switched over to the burn-the-planet work of ethereum mining.

Late last year I decided a full rebuild was due. Of course, there was a pandemic, and a world-wide semiconductor/microchip shortage, and Zen3/Ampere/Navi2 were nowhere to be found, certainly not at reasonable prices. Boo.

IT'S REBUILD TIME, MOTHERFLIPPERS!
Well now, thanks to a bit of patience, the goodness of OCAU forum members and spending a little too many of my dollarydoos, I now have:
ASRock B550 Phantom Gaming/AX mITX
  • AMD Ryzen 5 5600X + Noctua L9A-AM4
  • 2x16GB GSkill TridentZ 3600 C16
  • AMD Radeon RX 5700 XT (reference) -> (Pending delivery) AMD Radeon RX 6800 XT (reference)
  • 250GB SM961 + 500GB XP941 M.2 SSDs (to be upgraded eventually)
  • Silverstone SX650 650W with flat/ITX cables
  • A little bit of ARGB for funsies
eRCNoYy.jpg H7w9yLh.jpg 8k8hlOh.jpg QQcW03L.jpg 2TmQRO0.jpg
Team red all the way, with bonus grumpy bear and OCAU page

Uhh, "Portrait"? this is just an A4...?
Yeah ok, so here's the first "mod". Be warned it's fairly high tech and I haven't done detailed progress shots:
aDws0CT.jpg RM3hG1s.jpg CP4egnP.jpg
Step 1: Put rubber feet on the case front. Step 2: Stand up the case. Step 3: Plug in cables. Ooft, take a break.

:: ACTUAL MODDING STUFF ::
Wait, isn't the RX6800XT 2.5 slots wide? You bet it is, it's mod time motherflippers!


Here are the current problems to be solved/modded:
A) The DAN A4-SFX fits "2 slot cards up to 295mm", and I need to fit a 2.5-slot wide RX6800 XT.
Option 1: 3d print a spacer for the side panel
Option 2: 3d print a replacement GPU mount / shorten standoff from midplate to riser
Option 3: ???

B) The cables at the top are super-mega-ugly.
Option 1: make some sort of cover or replacement panel that for the 'top', use right-angle adapters and add front USB/pwr
Option 2: flip the whole thing over, add some feet so the 'rear' is now the base (issues with exhaust? not with the 6800XT!)

C) The lovely curved front of the A4 is relegated to a baseplate, boo, oh and I guess the power button and front USB are tricky to get to, meh.
Hopefully, solved by the solution for problem B, above

D) Because I don't like messy cabling I want custom-length cables
I have a Silverstone SX650 power supply, and need to buy/create only three cables:
1x ATX12V 24-pin -> ATX12V 24-pin
1x EPS12V 8-pin -> EPS12V 4+4-pin
1x PCIE 8-pin -> PCIE 6+2-pin + PCIE 6+2-pin
0x SATA
0x Molex

My 6800XT has arrived!

It's pretty immediately obvious that it's too big for the DAN A4-SFX.
- The length is clearly fine, as is the height, but it's a 2.5 slot card and the shroud fouls against the lip of the frame.
- It's currently "installed" by removing the riser screws/standoffs, and wedging it in place with the riser hanging freely, an iPhone charging stand serves as a makeshift stand to reduce tension
- Definitely not safe for portrait orientation!
6800xt-running.jpg

My plans to get around this issue are one (or both) of these options:
1) A replacement GPU riser bracket designed by Dan himself (posted on Hard Forum here, direct STL link: https://dan-cases.com/downloads/gpu_bracket.STL)
2) A side-panel spacer to add some extra space from the frame to the panel to allow the GPU to fit (Thingiverse link: https://www.thingiverse.com/thing:2771844)

I picked up a 2TB Crucial P2 today from the local computer shop. Not the highest performing drive but as it's only the storage/games drive, I don't mind.
I'll be waiting until PCIe 4.0 SSDs come down in price before upgrading the boot drive.

I've also ordered some extra parts to make this work, including:
  • LinkUp PCIe 4.0 riser,
  • Angled cables/adapters to reduce the cabling height,
  • USB Type-C panel mount connector (with USB-C front panel connector),
  • Momentary switch with a red LED power icon
Still waiting for the new riser, right angle DP and USB, and printed bracket.

But, nevertheless the PoC is functional:

seWLyen.jpg oVDAx1m.jpg 2POBGAw.jpg dPcCbwf.jpg

For the proof-of-concept, I used some parts I had on hand (except for the new 90 degree USB-C adapter)
2x Square adhesive rubber feet (Rubber Feet - Large Stick On - Pk.4 | Jaycar Electronics)
1x Aluminium laptop stand (Vertical Laptop Stand | Amazon)
1x Kmart 90 degree HDMI cable (High Speed 4K HDMI Cable 90' - 1.5m | Kmart)
1x Right-angle USB-C (USB C Adapter, CableCreation | Amazon)
1x USB-C to USB-A adapter (ARKTEK USB C to USB Adapter | Amazon)
Thankfully, as you can see above, the laptop stand parts provide just enough clearance for the HDMI cable.
The antenna wiring is definitely bent hard against the desk which needs to be fixed.

I also had to remove the original C13/C14 power socket extension from the rear panel, as the power cable (2M Upward Right Angle C13 Power Cable | www.powercord.com.au) I wanted to use is SUPER chunky. It may actually be bigger than a straight cable with a safe radius!

I'm debating whether or not to use panel mount connectors to relocate power and I/O to the base of the rear panel (previously the bottom panel).
Has anyone had experience doing this with displayport/HDMI? (I think Meshlicious has a ~25-30cm extension doesn't it?)

The GPU is a lot more secure now, I can shake the case and it doesn’t budge:
- Removed the square feet from IO end of the GPU,
- removed the plastic shielding (6800xt has full cover backplate anyway),
- added thin round rubber feet as spacers to protect the PCIe riser cable,
- added a thin strip of 3M Velcro adhesive tape between GPU/PSU

B08E0060-B4C4-4F11-A322-19939D16CF1E.jpeg 5235FAA9-3012-45BD-8BBA-66A2D70CAA12.jpeg

I also needed to work out correct lengths for PSU cables to make/buy, so cable ties and a ruler came to my aid:
BCA51A96-6FD4-40F3-8F9A-F599C94F16DC.jpeg FA4BB6D5-7879-4F72-AFFD-D00ECBEE2A25.jpeg 177C297B-6B23-458D-BD80-6B689115BB4E.jpeg

And here’s how they look installed:
E4A20906-7D70-49DF-8704-FCDFA4074014.jpeg AEF45672-9670-4BCD-BE04-7680C031A456.jpeg 2492F835-4B47-47FA-931B-FA2C7E18B90F.jpeg F2120A14-9182-4713-BA13-C90487F62846.jpeg F689653F-1B4F-4B5B-A4FD-F52173B04505.jpeg

I’m considering shortening one side of the wires slightly so that the cables have inbuilt curves, but not sure whether that impacts voltages / sensors, probably not with this kind of length at 16-18awg. Anyone know?

You’ll also notice in the images above, I replaced the 20+4 pin connector with a 24-pin one, and the 6+2 pin connectors with 8-pin ones.

Frustratingly, the 4+4 EPS is a different keying to the 8-pin at the PSU end (I was sourcing the connectors from spare PSU cables).

Now I’m fairly confident with de-pinning, I need to practice doing the crimps so I can be sure the pins will be physically and electrically secure.

Still waiting on the right angle DisplayPort, and haven’t yet decided what to do about the ports. Currently it’s working fine with a right angle HDMI and USB.

Debating whether I:
- integrate wifi antenna with case ?
- relocate IO ports (internal USB 3.x, DP, HDMI, C14 240v) ?

=== PLANNING UPDATE ===
So the right-angle Displayport cable works perfectly, and I'm fairly sure I'll move the C14 socket to the new rear of the case (previously the bottom).

I've ripped a pair of wifi antenna PCBs out of an old Asus antenna which I plan to integrate into the (yet to be) 3D-printed side panel extension to improve wifi signal without adding to the external protrusions, but needs to be plastic / non-metal to pass the radio signals through.

I'll also be integrating front USB-A / USB-C somehow, at the moment it's just a pair of right-angle extension cables, which works fine. The Link-Up USB-C front panel connector is a screw-onto-panel type, so it would have visible screws should I choose to keep it. I may end up getting the Lian Li one, which extends out further so the connector reaches the exterior wall but without visible fasteners.

=== OVERCLOCKING & BENCHMARKS ===
While I wait on some parts to be made or arrive (or even to be selected / funded) I've started doing some tuning.

GPU has been overclocked in Radeon software to 2567-2667MHz core with 950mV, 2150MHz memory using fast timings, 115% PL (with increased PPT via MorePowerTool)
CPU is set to PBO with +175MHz boost override, curve optimiser at 0,-15,0,-15,-15,-15
RAM (and Infinity Fabric) is set to 1933MHz CL-16 RCD-19 tRP-21 RAS-34 at 1.45V which required tuning a variety of RAM related settings. Might be able to squeeze a tiny bit more out with some more testing.

Anyway, the result is a slight improvement in TimeSpy bench results
:)

Will be very happy if I can crack the Top 10 of TimeSpy leaderboard (for 5600x/6800XT), was getting close but a couple of other high results in last day or two has pushed me back down to #14 again.
3DMark-TimeSpy-17597.png

So here's my quick mockup for a res-less (and sidepanel-less at the moment) design, trying to work out where I can shove a small combo res/pump, or if I can use a distro plate instead... might be better.

Design at the moment is made with some standard 2020 aluminium profile, so that it's relatively easy to get someone to cut, flat-pack & ship the panels & extrusions, with final assembly done at my end.

I have yet to work out how to do the RADEON lighting at the front, but it's intended to result in a frontpanel with a very similar look to the 6000 series Radeons.

::EDIT:: I also need to work out where I want to put (if any) front panel IO, and the power switch/LED.

Bare case:
upload_2021-8-27_17-4-44.png upload_2021-8-27_17-4-47.png upload_2021-8-27_17-4-53.png

With PoC-hardware installed:
upload_2021-8-27_17-5-4.png upload_2021-8-27_17-5-11.png upload_2021-8-27_17-5-17.png upload_2021-8-27_17-5-25.png upload_2021-8-27_17-5-29.png

I have no idea how the hell I'm gonna make this yet, and I'm fairly sure the tubing isn't particularly feasible... but:
upload_2021-8-30_13-20-35.png
upload_2021-8-30_13-21-1.png


Alternative no-riser layout, using the 2020 profile, wider (~180mm instead of ~130mm) but shorter in both other dimensions.

upload_2021-8-30_15-9-21.png

My 6800XT is same dimensions as the 5700XT pictured, but I don't have measurements and port locations of the EK FC 6800 block yet.

So the following is a guesstimate of tubing still. Will probably post this in extreme cooling forum to get some feedback as I don't know what I'm doing with tubing yet.

upload_2021-8-30_18-5-6.png


::EDIT:: sorry for the mad MS Paint skills, not sure how to do tubing in Sketchup's web app

Slightly zoomed, fans hidden, and less shit lines:
upload_2021-8-30_18-18-59.png


::EDIT:: Update:
Hard to see, but I managed to shave 20mm off the width, and 10mm off the height. Now 295x165x232 (+45mm depth for radiator out the back)
upload_2021-8-31_9-36-31.png


I did also briefly have a play with an open-frame air-cooled design:
upload_2021-8-30_18-53-30.png
upload_2021-8-30_18-53-45.png

But these are pretty available these days (if overpriced) and I want to slap water on my GPU so more advanced case is needed
;)

Pre-design Imgur dump:

Two reasons not to go with the open frame & air cooled design:
1) yep, I have a toddler who likes to put his fingers in things, prefer to avoid fans without guards
2) I've already ordered the watercooling kit & GPU block, may as well use it for the performance
;)

151528 said:
I like that first mockup, perhaps made a little wider to fit the pump/res in front of the cpu?
151528 said:
More potential for a perspex panel or two to show it off too
I'm considering whether or not I want an acrylic/TG window, leaning towards either mesh or window.
I wanted to have slat grills on either side and fans at the front, so the unit looks like a reference design RX6x00, but I'm not sure how to make it look slick or how the hell I'd practically make it.
151528 said:
Are you going to be making custom length psu cables once it starts to come together?
Yeah the plan is to make some custom shorty cables and route them as hidden as possible. I have considered either routed cable channels in acrylic/aluminium or a hidden compartment to make them as invisible as possible, but again tricky to design or make.

==================================

'Sandwich' design (https://forums.overclockers.com.au/posts/18985034/)
upload_2021-8-31_9-39-6.png

Dimensions: H x W x D = 332mm x 135mm x 235mm (+45mm to depth for radiator) = ~10.5L internal volume
Pros: Looks tidy, separated CPU/GPU, slimmer width
Cons: Taller / greater volume overall, requires the FLT pump/res (>$300 I think), v. complex to make, front panel gonna be a bitch

Riserless design (https://forums.overclockers.com.au/posts/18985039/)
upload_2021-8-31_9-40-4.png

Dimensions: H x W x D = 295mm x 165mm x 232mm (+45mm to depth for radiator) = ~11.3L internal volume
Pros: No riser needed, already ordered all WC parts, reasonably easy to make main frame
Cons: Honestly thought it would be smaller in this shape, but still comes to over 11L! (Compared to DAN A4-SFX at 7.2L), front panel gonna be a bitch

Open-frame design (https://forums.overclockers.com.au/posts/18985388/)
upload_2021-8-31_9-54-56.png

Dimensions: H x W x D 320mm x 185mm x 115mm = ~6.8L "internal" volume
Pros: shows off the original GPU cooler (schmexy), smallest footprint, easy & cheap to make
Cons: Lower performance and louder than using WC, toddler fingers + exposed fans are not a good mix


I've had a play with another layout.. Of course, to achieve these layouts I'd have to replace the pump/res I just got (EK-XRES 140 Revo D5 PWM Glass) with something much smaller (EK FLT 120 or integrated pump/res/block)

::EDIT:: An Alphacool Eisbaer LT would be perfect for this, as it includes the same pump but takes up MUCH less height than the taller Eisbaer version, potentially very tricky to fill/bleed though.

Using Alphacool Eisbaer combo res/pump/block:
upload_2021-9-24_16-42-9.png


Using an EK Kinetic FLT 120 pump/res:
upload_2021-9-24_16-42-53.png


Alt views:
upload_2021-9-24_16-44-4.png

upload_2021-9-24_16-44-9.png

upload_2021-9-24_16-44-13.png
Last edited: Sep 24, 2021

As such, below is probably the simplest, smallest and easiest vertical tower I can build. I haven't designed venting or mounting points yet, and certainly haven't added any prettifications that will be in my final revision.

184 x 168 x 304 mm = approx 10L total volume

upload_2021-10-6_22-59-3.png
 
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SFFMunkee

Caliper Novice
Original poster
Bronze Supporter
Jul 7, 2021
21
12

SFFMunkee

Caliper Novice
Original poster
Bronze Supporter
Jul 7, 2021
21
12
Did some extra work on the internal structure of Zen, but Sketchup online performance absolutely plummets when doing anything of reasonable size/complexity. I've even started getting graphical glitches as well so I'll probably move to Fusion360 sooner than planned, could be an interesting learning curve.

I have lots to go to finish a first draft of the Zen, e.g. I still need to finish planning the tubing runs, add an IEC socket for the PSU extension cable, decide on mounting/attachment method for the external panels. I'm still hestiant on the upright supports iin the corners, but could be used for mounting the external panels and supporting the frame (a la Velkase Velka3/5/7).

I've also recently ordered an Alphacool EisbaerLT, and a couple of 280mm radiators. I've already got a couple of 240mm radiators for testing as well. At some point I'd like to order a Nouvolo Aquanaut (combo or extreme) and probably an Iceman combo res/pump or EK FLT 80/120 res/pump. Then I can start building mockup proofs-of-concept and sense check the plans before moving towards prototyping.

Can't decide which style of case I like the best, probably leaning towards a tower style, but definitely still keen on working on the console style too...




 
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SFFMunkee

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So I got a new toy…

I’ll see how this goes as a block / pump.

I’m considering also testing 2 separate loops with 240mm or 280mm rads, or combined loop with dual rads and a single pump.

I’ll find out if the LT pump can handle it, if not I’ll be ordering myself a Nouvolo Aquanaut!


 

SFFMunkee

Caliper Novice
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Jul 7, 2021
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I've been working on two different versions of the vertical tower.

One (ZenChonk L) with greater capacity for fat (but not ultra-long) GPUs and dual 240mm radiators. This would bring the volume up to 12.2L, and requires a PCIe riser, but it significantly expands compatibility and ease of installation, the other (ZenChonk S) with the smaller volume but only capable of taking the single radiator & single-slot W/C GPU.

I've also been working on the mechanical attachment of panels, while keeping to mostly individual pieces for flat-pack shipping options. Haven't decided whether or not to keep the tri-fold cover plate (like the AT computers of old!) or move to separate side/top panels.

ZEN CHONK L
Dimensions as shown:
Width 154.2 mm
Height 312.2 mm (exc 15mm feet)
Depth 253.6 mm
Volume = 12.21 L (plus feet)








ZEN CHONK S
If I want to keep the volume/dimensions as small as possible, and restrict to single-slot, ~280mm GPU, and single 240x45mm radiator then I can get it down to approx 9.3L:

Dimensions as shown:
Width 162 mm
Height 297.9 mm (exc 15mm feet)
Depth 192.4 mm
Volume = 9.3 L (plus feet)




Test Setup
I set up a roughly-equivalent, but open, layout to the ZenChonk S (although I accidentally placed the rad the wrong way around so the PSU can't currently fit behind the rad where it should) and tested it. The tubing you can see off the EK 45deg fitting is a makeshift reservoir. This allowed me to bleed the air out, after which I drained the res-tube and fitting, and capped off at the T-fitting.

You can see the Corsair SFX PSU behind Grumpy Bear's head, the rad is sitting atop the backplated GPU and the motherboard is slid onto the GPU via the PCIe slot. Thin foam sits underneath the GPU and between the rad/GPU which keeps things relatively stable. I wouldn't want to leave it like this permanently, but it's secure enough that I could (carefully) pick up the whole rig and turn/shake it to help bleed out the remaining air.



Thermal Testing:
I have determined that the single-loop with Eisbaer LT & 240mm XT45 is sufficient to cool CPU & GPU if not heavily overclocking. A 1-hour OCCT run had both peaking around 80C with about 115W + 292W according to HWInfo64.

At regular usage it's completely inaudible, and even when pushing hard it's not an obnoxious sound profile, thanks to the 2x120mm Air Blazers which are surprisingly tolerable sounding fans even at 100% rpm.

Will do some further thermal/noise tests later, and continue with planning the case design(s).
 
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