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NZXT "Bio-Mechincal" Khaos Project

Last response: in Components
February 26, 2009 9:31:20 PM

The KHAOS case arrives at

At the end of video, I debated about doing a giger (alien movie) or watchmen, I've chosen the bio-mechnical theme. Heres one of my favorite HR GIGER paintings, "Landshaft XIX" Theres so many details!

Heres the entire bay assembly removed from the chassis.

Whats your remedy for a headache?!

This is the housing from a small motor I found. I love the design. The skull will be hosting the system Power & Reset switches (22mm & 16mm lamptron vandal switches, w/orange leds) The mounting plate I made (below) attaches to the upper half of the skull.

NZXT Khaos panels look cool, but the hang out in the wind... Maybe keep them and do BATMAN theme

We made these 1-1/4" thick, 6061 aluminum. 6.5" O.D front intakes,

February 26, 2009 9:44:43 PM

February 27, 2009 5:27:26 AM

Let's see a final picture of the completed project.Looking good so far.


LG 24IN WS LCD 1920X1080

February 27, 2009 11:22:33 AM

It's not finished yet

"Hey, It's Spin Art!" :D 

February 27, 2009 1:05:06 PM

The intakes look superb
February 28, 2009 10:00:39 AM

Albertwacca said:
The intakes look superb

Thank you, Pre-fitting skull and intake covers now.. I need to fab a 5.25 cage above the skull, thinking I may salvage a quick release style 5.25 bay from the old chieftec dragon tower. Imagine if the skull matte blackalready.. Yum, but I'm still working on detailing the skull, so it will be awhile before I paint it.

February 28, 2009 10:05:55 PM

This weekend my focus will go back to adding more details to my friend, Skully.

My Magic Sculptarrived, after receiving the wrong product, Magic Smooth. I can't blame them, the product labels are very similar. Tap's customer service is one of the best I've ever dealt with. They took care of everything quickly, answered emails, and called to follow up with me about crediting the balance on my credit card. Very friendly over the phone. They're the business I strive Mnpctech to be like.

ARTbyTROY posted an excellent comparison of sculpting compounds for case modding. His article prompted my decision to try Magic Sculpt.

Sculpting Tools I chose
March 2, 2009 1:23:14 AM

I started with the skull today, adding mechanical aspects, like these vented and screw joints.

I will dremel details in these sculpted parts, 24 hrs after Magic Sculpt has fully cured

Small pan head machine screws

It only takes a few drops of water to smooth the surface of Magic Sculpt

Hex Nut with tooth washer doubles as port for plastic wire loom

March 2, 2009 11:00:44 AM

Last night I worked on the chassis.

This 1/8" thick aluminum plate will reside underneath the foam/fiberglass top panel, which later will be sculpted with proper ventilation. In this case, a BIX 240 Stealth radiator.

I posted radiator template print-outs you can download. (PDF Files)

Before printing, you must select "None" for page scaling in your print dialogue box!

Download Page for each template

Radiator Templates Download Page

my center punch

March 2, 2009 7:44:33 PM

Top 240 rad mount, 1/8' thick aluminum plate

low brow art?

a b ) Power supply
March 2, 2009 11:00:40 PM

Very nice. Get some WC set up to go with the awsomeness.
March 2, 2009 11:25:32 PM

God damn it monstermawd you are a god at this. Everytime you post I want to run out and dremel and paint the crap out of everything, wish I had the time for a case mod. This one is particularly kickass since you are taking a monster of a case and making it into something even more beastly! Just bookmarked this thread so you can be sure I'll be watching!
March 2, 2009 11:49:23 PM

Comment on the video, my Silverstone TJ07 came with a dual PSU jumper like the one in the Khaos case and it was sleeved as well, black and green. Two things pop out to me about that case:

1: Overpriced, it just does not have look like it has the quality other $300-$400 cases and it seemed to be designed with looks and wow factor in mind, and not balanced function.

2: It just does not look like a good watercooling case even with mods. It is a bit tight in there and seems like it would be a bitch to run thick tubing in it.
a b ) Power supply
March 3, 2009 12:30:50 AM

I want to run out and dremel and paint the crap out of everything,

Yeah, I know the feeling...
March 5, 2009 12:39:58 AM

Thanks for the comments guys!, back to the bench for this project today, Black Plastic loom in (1/4" and 1/2" diameter) will be embedded and intertwined throughout the bezel and top panel. The entire skull will be painted matte black

a b ) Power supply
March 6, 2009 8:08:14 PM

Quick question, exactly how thin/thick are the walls of the tubing you are using for the loop?
March 7, 2009 12:50:43 AM

I havent decided on tubing yet. I'm still modding the case.

I carved a basic shape first, for the bezel. Then I'll carve and sculpt notches and crevices into it

a b ) Power supply
March 7, 2009 12:49:13 PM

I havent decided on tubing yet. I'm still modding the case.

Sorry, I meant the black tubing on the skull. I thought you were using that as part of the loop.
March 7, 2009 2:24:11 PM

Shadow703793 said:
I havent decided on tubing yet. I'm still modding the case.

Sorry, I meant the black tubing on the skull. I thought you were using that as part of the loop.

Wow that would be sick. Run 1/2" or 3/5" tubing through the tubes in the skull. Though it would put MM's watercooling skills to the test trying to bend that tubing like that. I for one like rigid and thick tubing that I know wont break. As cool as it sounds, I'm not sure it would be practical. That said, how much of case modding is practical?
March 7, 2009 2:25:56 PM

With some good dye (especially red) in the liquid you could light up the inside of the skull in a very menacing way, that would really draw the eye.
March 9, 2009 10:44:02 AM

I see what you mean, I'll probally make the loop very inconspicuous. I hate having water lines in the way when i need access hardware.

If you've ever examined giger's bio-mechincal art up close, especially his paintings.. everything is symmetrical, in one direction while every element of the design is different. Old circuitry is the only way I can describe it. Theres a massive amount of detail. I can already tell it will be overwhelming at times if I'm not in the mood. Theres just no way I or anyone else will come close to replicating his work. You can only draw upon it as inspiration for your own style.

My personal challenge with this project is that my brain likes to see everything symmetrical and matching. "Theres a notch on the left side, so there should be a notch on the right side" I have to force myself to stop thinking like this. However, I also think a lot of people neglect to see these details in his work and it doesn't matter as much I think it does.

giger's "New York VIII" painting

March 10, 2009 12:23:04 AM

Skully is now painted, Matte Black, and hes gone back into his 5.25 column

a b ) Power supply
March 10, 2009 10:11:50 AM

Just too damn amazing, I just really wish you'd go with red, red and black is just pure amazing.
March 10, 2009 1:12:04 PM

Thanks! :D 

Heres the tools I use to sculpt the insulation foam, but it's always good to experiment on your own.

To cut thick foam, I use a snap-off blade utility knife.

To smooth the pieces, I use a Surfoam Shaver by Stanley Tools

For making intricate details in the foam, I'll use an array of the tungsten carbide cutter bits from Dremel, I mainly use the #9911

a b ) Power supply
March 10, 2009 8:08:25 PM

Quick question, are you going to put any kind of hardener on the foam, so that when you bump in to it it won't dent?

PS: I'm following your project on acidmods too :) 
March 12, 2009 9:46:13 AM

Yes, fiberglass filler.. I just posted this video explaining more about it

Some of you should recognize this, it's a universal euro license mounting plate.
The recessed features and fastener holes play the part in my theme.

Applying Evercoat Everglass fiberglass filler

I've cut portions of the license mounting plate to fit the sides of my bezel

March 12, 2009 9:48:08 AM

Nice MM, I'm real excited for this one.
March 14, 2009 12:52:45 PM

Thank you! Next stage is to cove the foam core with Fiberglass Filler, sand that, then sculpt more features. Pondering idea for adding ribbed spines to the circular frames for the 3 intakes.

March 22, 2009 10:08:34 PM

Found time today to get outside and start the process of smoothing out the fiberglass filler.

I'm predicting another week of sanding and grinding before the surface will meet my expectations.

I'm armed with Filtered Respirator, Black & Decker Mouse Sander and 120 grit sandpaper.. Let the transformation begin!

Note: This is Evercoat brand's Everglass "Short Strand" Fiberglass Filler

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a b ) Power supply
March 23, 2009 3:50:30 PM

120 grit? Wouldn't 80 be faster/easier for this kind of work at the start?
March 26, 2009 12:33:08 AM

Yes, and I need to edit that to 80 grit. Thank you

I predicted a week of sanding and grinding the filler in the bezel, but I'm gonna request a time extension.. lol

Any pin holes or pock marks seen will be filled again

April 15, 2009 10:57:16 AM

After more grinding today, I applied the 2nd layer of filler to areas of the bezel. I'll pre fit the plastic loom tubing next
April 15, 2009 3:20:42 PM

This is simply amazing!, I've been looking at this work and i have to say you have AMAZING skills. Good Luck!!
April 15, 2009 11:01:35 PM

Heres after sanding the 2nd application of Evercoat brand "Everglass: (short strand) fiberglass filler. I thought this would be the final coat, but I'm not satisified with the results yet. btw: I'm recording stages of the bezel for YouTube after getting several requests offlist. I'll remember to edit out all of the boring!

April 17, 2009 9:44:59 PM

Test fit it tonight, touch up some details with spot filler, re-install the threaded rod and then I can apply the base coat to the bezel

April 18, 2009 1:50:35 AM

Very good work. My many attempts at case modding have been half assed and turn out poorly.
April 18, 2009 1:24:00 PM

Thanks, awesome avatar btw Trap

Test fitting the bezel onto the chassis and cut the wire loom tubing

a b ) Power supply
April 19, 2009 5:13:02 PM

April 19, 2009 9:41:41 PM

Thank you! I wired the 3x 120mm front intake fans, yippe!... I'd like the leds a tad dimmer tho

April 19, 2009 9:54:00 PM

The LEDs look great to me and work well with the case.
a b ) Power supply
April 21, 2009 1:18:07 PM

^+1. I don't think it's too bright.
April 21, 2009 4:44:24 PM

Case is looking very nice... I have started my own case build from ground up. This is alot of work, and I have to say looking at your case mod, and seeing my case build, it is worth all the work. Keep us posted with pics, I can't wait to see the end results of your project.

NZXT case's are awsome case's to work with, I have a Tempest and have only modded the glase panel with smoked glass on mine. My new case I am building from scratch is all aluminum with 1/4" granite on the inside and the top outside and front.

BTW the LEDs look great on that monster!

a b ) Power supply
April 21, 2009 8:38:54 PM

Quick question, how thick is the metal in the case? On some cases manufactures use 1/8" Steel which is a b!tch to cut out.
April 26, 2009 10:37:45 PM

Thanks for the feedback guys!

The case is aluminum, you'll have to check their product specs on their website

Applied Black Spot filler / sandable primer this afternoon. Nice change from Green. Gives you a better idea of how the final piece will look. It also helps reveal what areas of the filler I wanna keep touching up.

April 26, 2009 10:49:33 PM

Hey monster,

I saw what you guys did with the Antec 300 case and loved it. You do very nice work. I just finished my new case i built from the ground up, I think it may be the first case ever built with Granite, LOL> I thought about putting out the money for The NZXT your modding, but decided to build my own instead. Keep us posted with pics, I can't wait to see what it looks like.
April 27, 2009 1:50:13 AM

Looking good MM, I think this is one of the most natural ideas you have had yet. This case almost seems like it was built for this mod, even down the the name Khaos.
April 27, 2009 9:46:52 PM

Thanks for the great comments and support guys!

The bezel looks much better Black than Green.

April 28, 2009 4:19:45 PM

I don't know what hardware I'll be installing. still waiting from potential sponsors who expressed interest, but haven't followed up with me yet. I'll just keep plugging away on the exterior.

still need to tweek down led fans, no biggy tho

April 28, 2009 7:49:13 PM

Quick question, will you be going for fan grills MM? I could see how the styling would be better without, but it could be a problem. Then again you could always put removable grills behind the fans to get the best of both worlds.
a b ) Power supply
April 28, 2009 7:51:21 PM

Nice! Any chance you could get pics in the dark?