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Thread: Project Log: Hail to the King

  1. #1
    Primered
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    Project Log: Hail to the King

    This project was commissioned by NVIDIA as a gift to Gearbox for the launch of Duke Nukem Forever. Partners in this project include:
    NVIDIA - Financed the project, project manager was Kris Rey, Community Manager from NVIDIA. Special thanks also go out to Eric Liu, Leslie Pirritano, and Mike DeNeffe (all NVIDIANS) for making this project happen. Sean Wix and Tim Springer from NVIDIA were patient enough to let us use their lab space and provide trouble-shooting to get some insane dual-screen 3d action going.
    EVGA - supplied Classified 3 motherboard and two Hydrocopper 2 580s
    Danger Den - Laser cutting services and all water-cooling at a nice discount
    Crucial - killer Ballistix Smart Tracer ram and two SSDS
    East Bridge Manufacturing - Discounted metal fabrication services - hub and mini gun came out beautiful!
    BoxGods - insane design that make the project so much easier
    ASUS - two 23" 3d monitors
    Frozen CPU - nice discounts on various parts especially the UV Green wire for the PSUs
    Silverstone - 1500 watt PSU
    Fernando from Painters Supply in Salem Oregon - busted his tail to help get skin painted in time
    The guys at Mid Valley Metal works for the use of their HUGE powder coating oven for bending the skins
    My wife Delia who helped me heat bend the pod skins and who put up with the mess in our great room while I built this puppy
    and my best friend (next to the wife) Chris Fletcher who gave up his time to travel with me to NVIDIA to complete the build
    Gearbox and 2k for making the game and supporting this project!!!

    I will not reproduce everything in the Geforce.com article found here http://www.geforce.com/#/News/articles/nvidia-presents-the-duke-nukem-forever-pc-mod but will instead add to it to provide more details and allow you to give feedback. Geno and I feel we want to not only produce worklogs to publicize the project but also to make the worklog a learning experience and to give back to the community. This worklog will be spread out over a a week or so - please keep checking for updates.

    As stated in the article, we had several concepts for this project which were considered before arriving at one which everyone liked. My first submission was a school-girl themed design. I will not go into too much detail on this one but you can figure it out if you look at some Duke artwork. The second concept was the single Duke logo with buildings on each side.



    If we used this concept, I would have included some pretty insane miniature buildings.


    Geno, true to form, came up with a few twists "just in case" we wanted to go in a different direction. This was his just for giggles concept:

  2. #2
    The Main Man Dewayne's Avatar
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    Project Log: Hail to the King

    Awesome project man!

  3. #3
    Primered
    Join Date
    May 2008
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    Project Log: Hail to the King

    Once Geno had the Solidworks drawing done, Danger Den set to work cutting the acrylic. Here you see some of the pieces from Danger Den


    Geno had East Bay Manufacture fabricate the hub and gun







    Used a wooden buck to heat bend the acrylic the round shape needed to skin the pods



    The first effort bending did not produce a perfect result. Had to reskin the buck as the vinyl flooring did not work well

    Before bending:



    After first bending






    After second bending









  4. #4
    Primered
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    Project Log: Hail to the King

    https://www.youtube.com/watch?v=NMT5dWeNscg&feature=player_embedded

  5. #5
    Primered
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    Project Log: Hail to the King

    Needed my Wonder-Twin g33k powers to complete this project:




    Jig for drilling and tapping holes in end of rib sections:



    Counter-sinking holes



    Gluing the pod covers to get them ready to paint:


    Tapping the manifold:



    Getting ready to leak test the manifold:





    http://www.youtube.com/watch?v=5ceqTuhlBi4"[/video]]Duke Manifold Leak Test

    The next step was to glue the skins onto the pods. I used Weld-On 3 - a thin glue which uses capillary action. You apply it to the seems with a syringe.


    Making the window bubblers. Layered 1/8 UV green acrylic . . .stripped down hypodermic needles so air could pass thru them at a reasonable rate









    http://www.youtube.com/watch?v=J4ccjDQIX28"[/video]]The Reservoir

  6. #6
    Primered
    Join Date
    May 2008
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    Salem, Oregon, United States
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    Project Log: Hail to the King

    Need to take the monitors apart to paint the enclosures




    Masked the pods so there would be windows left after painting - paint done then pack it all up for roadtrip to NVIDIA HQ . . .




    All the stuff laid out at NVIDIA HQ



    Installing the floating PSU







    All the pods in place looks pretty good



    Installing the mobo





    Let's get those monitors on . . .Epic mod time! Should wrap them in bacon and deep fry them?



    Tomorrow we will look at the PSU and rad pods close up - and then get it all fired up including some video

  7. #7
    Primered
    Join Date
    May 2008
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    Project Log: Hail to the King

    Today I will go back a few steps to show you how I rounded the edges on the case ribs and how I polished and drilled the screw holes in them.

    The first technique is to use wet sandpaper starting with a rough grit depending on the surface you have after cutting or routing. Here I work my way to 1000.

    http://www.youtube.com/watch?v=sRvC1pdO3UM"[/video]]Wet Sand

    The next step shows routing the edges then using a polishing wheel with Novus 2.

    http://www.youtube.com/watch?v=fhZBM3-Bl9w"[/video]]Routing

    I made ghetto jig to drill the holes in the end of the ribs which I later tapped to M4 screw size

    http://www.youtube.com/watch?v=SMC9W3C1JIg"[/video]]Drillin

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