Dell Optiplex 960

Which version of Optiplex 960 do you have? The desktop version uses a BTX format motherboard and Dell uses proprietary connectors in many of their Optiplex products. The SFF version is even more proprietary.

ftp://ftp.dell.com/Manuals/all-products/esuprt_desktop/esuprt_optiplex_desktop/optiplex-960_Service%20Manual_en-us.pdf

You would be better off leaving the 960 guts in the original case and adding upgraded components to it.

yes it is BTX case, which model you have, please identify



And what are you planning to upgrade, by the way, you budget and your geographical location.

Is this your other build is Optiplex? Or something else?

What was defective, do you know, I am asking this because 630i is overclockable with certain processors, and I know how!

Where did you find that Q6600 is compatible, I did not see it on the list of processors shipped with Optiplex 960

Intel Quad Core processors
Intel Core 2 Quad Q9650/3.00GHz,12M,1333FSB
Intel Core 2 Quad Q9550/2.83GHz,12M,1333FSB
Intel Core 2 Quad Q9400/2.66GHz,6M,1333FSB

Intel Dual Core processors
Intel Core 2 Duo E8600/3.33GHz, 6M, 1333FSB
Intel Core 2 Duo E8500/3.16GHz,6M,1333FSB
Intel Core 2 Duo E8400/3.0GHz,6M,1333FSB

link http://www.dell.com/downloads/global/products/optix/en/desktop-optiplex-960-technical-guidebook-en.pdf

Anyway, you can not use 630i heatsink, because Optiplex has proprietary motherboard mounting, you stuck here.
However, check how your heatsink looks like, do you see any yellow parts there, if yes, you have copper heatsink, if not you have aluminum. Quads require copper one as most efficient, aluminum is only for Core 2 Duo.

There is the way to place many more fans in this case to improve airflow, this is for the next post, I need to find this info (have it somewhere).

Video card. The maximum today available is 7770, which can fit, let me explain. I use this post before and some links there might be wrong or discontinued, anyway take a look.

THIS POST APPLICABLE TO MT (MINI TOWER) FORM FACTOR ONLY.

Unfortunately no card that is more than 7.5 inches long or 2 slots wide will PHYSICALLY FIT inside the case - it was found that only single bracket video card can fit due to BTX MOBO, where card internals facing upward towards PC internals, not ATX, where dual card design is blocking another PCI slot by facing downward.
If you prefer the card with beefier fan, then the length of the card must not exceed 7.5 inches, otherwise only "skinny" single bracket, single slot cards can physically fit.

Pictures below will prove my point.

View shows no room for dual bracket



Single bracket only, or you have to cut dual bracket in half



Here you can clearly see only single place for the bracket



Visual explanation



7.5 inches explained, also shown "obstacles"



This is the picture of actual "skinny" single slot video card (not sure which model)- perfect, "glove" fit.



So, I found 2 GDDR5 7750 cards and one DDR3 4GB (GDDR5 is better than GDDR3, even if GDD3 offers 2 GB RAM or more), which confirmed in reviews to fit Optiplex gx620, 745 and 755 cases (the difference between those models are different processors).

Skinny, flimsier in terms of construction, completely single slot XFX 7750 http://www.amazon.com/XFX-DisplayPort-PCI-Express-FX775AZNP4-FX-775A-ZNP4/dp/B007Z3T5JC

A bit beefier cooler, not as skinny, more durable in construction PowerColor AX7750 http://www.amazon.com/PowerColor-AX7750-1GBD5-DH-Video-Graphics/dp/B00775OC28/ref=sr_1_1?ie=UTF8&qid=1362783129&sr=8-1&keywords=AX7750+1GBD5-DH

If you need Video card for working with high resolutions, BUT NOT FOR GAMING, PowerColor AX7750 4GBK3-H Radeon HD 7750 4GB is DDR3 card with huge 4GB memory, but is is not as fast as DDR5 and loosing in games http://www.newegg.com/Product/Product.aspx?Item=N82E16814131486&Tpk=7750&IsVirtualParent=1
Here is review of this card http://news.softpedia.com/news/PowerColor-Launches-Single-Slot-Radeon-HD-7750-4-GB-Video-Card-292712.shtml so this one is not for gamers!

I cannot say which one of those 2 DDR5 is better, both are good and got less bad reviews related to structural build.
I saw recent recommendation regarding drivers "Changing to the just-released AMD catalyst 13.2 BETA driver improved performance noticeably in just about every game" posted 03/05/2013. So older drivers are worse, can not comment about the newer ones, so this part is take it or leave it.

Next will follow maximum possible upgrade, 7750 is weaker...

So far I found only 2 7770 video cards which will fit inside - PowerColor AX7770 http://www.newegg.com/Product/Product.aspx?Item=N82E16814131477

HIS H777FN1G Radeon HD 7770 very tight fit, almost touching heatsink http://www.newegg.com/Product/Product.aspx?Item=N82E16814187200

From NVIDIA I see SPARKLE 700025 (SX650TI1024KD) GeForce GTX 650 Ti http://www.newegg.com/Product/Product.aspx?Item=N82E16814187200

7750 cards do not require power supply upgrade, 650 TI and 7770 are.

There are so many options available here so I would just recommend one of the good one CORSAIR CX500M (modular), which has just enough power http://www.newegg.com/Product/Product.aspx?Item=N82E16817139050 Also, with modular you can get rid of extra cables, believe me there are a lot of them.
You need 500 watt at least, stronger is better depending on your money.

You said in the begining that you want to make Frankenstein, I am ready to help you, but I need your help first

Can you make measurements in metric system preferably, because FANs measured in mm, so measure please A, B, C, D from the below picture - this is for additional fan placement. I have an answer already, but for a little bit different model, so I need to make sure that it will fit.



Regarding the CPU Q6600, I am not saying it is not possible, I just did not see one yet, so it is completely up to you, however I am about to help you with excellent cooling, so I need your help first.

Thank you I got the measurements.
Do you have any fans left from XPS 630i?, I am thinking about 1 up to 120 mm extra fan in the front, to be attached to the front panel from inside and maybe 2 80 mm fans, or one 120 mm fan in the back attached to the mesh to work as exhaust - all when you upgrade CPU to aid with cooling, if necessary.

Regarding Q6600, again, if you sure, then go ahead (if you remember where you seen it, share the link), I just did not see this option, if you can find the one I offered, especially one of those
Intel Core 2 Quad Q9650/3.00GHz,12M,1333FSB
Intel Core 2 Quad Q9550/2.83GHz,12M,1333FSB
This would be awesome!

Two 120 mm fans could be enough - check if you can remove Dell logo button in the front and see if you can attach this fan from inside to outside panel, connections later. Just take the fan inside the hole between CPU fan and front panel, does it fit? Can you see that at least 3 mesh holes line up with fan screw holes?
Check the same for the back mesh and 120 mm fan.

If both fans can be physically attached, tel me how many pins are on each fan, I will advice on wiring.

Before you will need to add additional fans, I don't think you mentioned anywhere about your current CPU cooler, is it aluminum or copper. Look at the picture below, compare to yours (use a flash light directed at your CPU cooler, if you see yellow parts, it is copper)



Left is aluminum, Right is copper.

If yours is copper, most likely you don't have to do anything else, if it is aluminum, changing to copper might solve cooling issues, price wise and headache wise, changing CPU cooler is a clear winner, since you would have to remove your CPU cooler anyway to change processor. Dell places copper version on all Quads.
Your aluminum and copper coolers have different parts numbers, compare to the picture. Pictured is Optiplex GX620, which is similar, but may not be the same.

If additional fans needed, 120mm will go to the front and you would have to place 2 80mm fans in the back. Those fans would have to be connected directly to PSU through special connectors, more things to buy, that is way, additional fan upgrades usually coming if copper CPU heatsink is not enough!

So, lets do one thing at the time. First check your cooler, aluminum or copper, if copper let it be, if aluminum let me know, I will find copper for you, second, get processor and Arctic 5 thermal paste, remember to clean with at least alcohol all parts prior to applying new thermal paste.
Once everything is connected together, get OCCT (my preferable monitoring and light testing gadget) http://www.ocbase.com/

Check your temps and post them here, then, and only then we will figure out next steps.

There are no aftermarket heatsink offerings for those BTX Dells.

I can not use PC to check, only iPhone now.
Are those temps done with aluminum? I like you copper links, will verify tomorrow the proper fit.
Have you upgraded your power supply, due to iPhone limitations cannot scroll easily here, ugh.

You can mount a standard ATX PSU (and just live with the gap) and the system will perform well. You don't need a Dell PSU.