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STAR TREK Case Mod for Comic-Con

Last response: in Components
June 2, 2011 5:10:38 PM

A Star Trek case mod theme that will be stylish.. Er, I mean Chic!

Maximum PC has a presence at Comic-Con every year as an outreach opportunity—to let the hardcore comics and sci-fi fans know that PC enthusiasm goes hand-in-hand with that kind of fandom. This year we’re using our booth as an opportunity to show the fans at Comic-Con how awesome a great case-mod can be and how PC geekery and sci-fi enthusiasm can meet in a beautiful way. So we’ve hired the best guys in the business to design and build an awesome Star Trek-themed PC, and we’ll be giving one away at Comic-Con and the other one will go to David Gerrold in exchange for some writing he’s doing for us in relation to Comic-Con. - Nathan Edwards, Senior Associate Editor

Conceptual Designer: Mike Okuda is graphic designer who has worked on Star Trek series since the 1980s and is responsible for much of its visual style, including the LCARS interface as seen on Next Generation.

Matt Jefferie's original design of the Tricorder served as Mike's inspiration for styling cues on the "Tricorder Shiek" computer case
design. We could have scratch built a PC that looked just like the Tricorder, but David wanted an actual computer case instead with specific utilitarian features like hot swap bays and a compartment for his Tribbles.

3D design of "Tricorder Shiek" by Dave LaLopa

Top panel and storage compartment

Top panel will be milled from 2" thick 6061 aluminum

This Lancool K-58, manufactured by Lian Li will sacrifice it's chassis to this project.

Lancool K-58 chassis will be painted Matte Black Enamel.

Using Rounded side hand file to smooth the cut edges.

Using Red Scotch-Brite pad to scuff the surface in preparation for Primer base coat.

Lancool K58 chassis painted Matte Black Enamel (1 for david, 1 for comic-con)
Machined aluminum computer case feet,

Machined aluminum computer case feet with grooved edges.

The aluminum feet are machined on CNC Lathe,

The bare aluminum is nice contrast to the Matte Black.

#10 x 5/8" Black Oxide Fan Screws,

Screws will be used in conjunction with fan silencing rubber grommets,

#10 x 5/8" Black Oxide Fan Screw inserted in rubber grommet

We are installing Yate Loon Blue LED 140mm cooling fan

Lian Li Tool-Less PCI Card Holder, 7 x PCI Holder. Works with many Lian Li cases or other modified cases. Specifications: Tool-Less PCI Card Holder, 7 x PCI Holder. Designed for Most of Lian Li Cases. Dimension (W)70mm x (H)145mm x (D)30mm

Add your own Caption!!!
June 2, 2011 8:23:40 PM

Picking up following material list in morning.... 6061 aluminum

1.938 thick x 18.1875 x 8.25 (2 pieces)
1.5 thick x 8.25 x 5.906 (2 pieces)
1.4375 thick x 14.969 x 8.25 (2 pieces)
.4375 thick x 21.25 x 21.125 (4 pieces)
.25 thick 1.625 x .3125 (2 pieces)
.125 thick x 8.875 x 7 (2 pieces)
.125 thick x 20.5 x 20.375 (4 pieces)
.125 thick x 8.578 x 7.5 (2 pieces)
.125 thick x 1.82 x 1.11 (2 pieces)
.125 thick x 8.1875 x 3.219 (2 pieces)
June 3, 2011 5:39:28 PM

We will be swapping the hardware from NZXT's 5.25 bay Sentry Fan Controller into the top cover, available from performance-pcs, here

E.E.L Ambiense is having fun with making captions too!

Related resources
June 4, 2011 11:48:06 AM

Hey Kids, It's Billet on a skid!

I was focused on making a dent in our work load, so I didn't take a lot of photos last night...

First layer is 1/8" thick smoked grey, cast acrylic.

these will 3/16 mounting holes

Starrett spring loaded center punch..

Using counter bore bit to debur holes


(hint: my lanboy air review)
June 5, 2011 10:54:41 AM

This morning I'll be sleeving the Sentry this Silverstone FP34S Premium 3.5inch Bay Card Reader & Front I/O combo module, David chose this model mainly for it's card reader and headphone jack. It's from performance-pcs here It will be mounted in the new top panel. I chose Bulgin's "Orange Dot" for the Main Power button from performance-pcs, here

The Sentry's display screen will be mounted in the top bezel opening. A 22mm Bulgin "Orange Dot" vandal resistant switch will be the Power button.

another caption by EEL :clap:

June 5, 2011 7:33:39 PM

3.5" HD trays painted Red Enamel and HD cage painted Black Enamel.

another caption by EEL!

a c 87 ) Power supply
June 5, 2011 9:01:12 PM

I am watching this.
Also enjoying the captions.
June 5, 2011 10:37:05 PM

Silvune said:
I am watching this.
Also enjoying the captions.

Thank you for tuning and commenting Silvune :) 
June 6, 2011 11:37:33 AM

Mike and David worked on TNG series as well. Maybe they would be open to doing a TNG for next year's Comic-Con.
June 6, 2011 11:57:30 PM

Tonight we'll be milling the aluminum panels and inlay plate for the side panel with the USS Enterprise (NCC-1701) design, which will be slightly larger than whats show in this screenshot.

The top cover will have a compartment...hmm for what?

The compartment lid consists of one sheet of 1/8" thick aluminum and 1/8" Opaque red cast acrylic

June 7, 2011 12:52:38 PM

Thank you!! :) 

Last night the larger aluminum side panel plates took two hours apiece to mill. They exceed the travel space of the mill, so they had to be re-positioned for each side.

Made a temporary Tapping block as guide when manual tapping blind screw holes on backside of the larger aluminum panel.

Blind hole tapped for 8/32 machine screw

Caption by EEL!

June 7, 2011 11:16:39 PM

Sanded edges and removed mill trails on the aluminum panels today.

The opinions expressed in this project log are the views of the Modder and do not necessarily reflect the views and opinions of the parties involved with the project.
June 8, 2011 1:39:23 PM

USS Enterprise cut in 1/8" thick aluminum exterior plate.

June 8, 2011 6:17:32 PM

Finished 1/8" thick Opaque Red acrylic plates in the mill. They will mount inside the machined aluminum exterior plates, as shown in drawing... I'll mount these this afternoon

June 9, 2011 2:38:56 AM

Worked on the side panel pre-assembly today> The inner wall of the steel panel needs to be painted Black.

June 9, 2011 2:19:11 PM

I need to stealth the LG's Black Blu-ray Drive they chose for each of the two builds

SATA Model UH12LS28 OEM LightScribe Support - OEM
4 MB Cache
1/8" thick billet plate to be used for stealthing the drive tray

June 11, 2011 11:44:13 PM

The trim piece for the Bezel, Hot Swap & Top compartment doors are being laser cut from 1/8" thick Red Opaque Cast Acrylic. We're using a single 75 watt, 24" x 18" Platform "Universal Laser Systems" machine. We use this unit for making retail PC fan and radiator grills. This unit if new, would be priced between $19K - $25K. We don't offer laser cutting as a service, but these guys do! Laser Cutting Service, Inc. offers custom laser cutting to PC builders, modders! hobbyists.

Laser Cutting Service, Inc.
803 41st Street North
Birmingham, Alabama 35212
205-595-7070 FAX 205-595-7021

June 15, 2011 9:35:41 PM

Next step is making the "H" frame piece for the lower portion of the bezel, from 1.5" thick aluminum. This will have an engraved "David Gerrold" signature plate (white square, 2nd pic). Each of the cases will have two ICY DOCK MB877SK-B Tray-less Aluminum Body 3.5" SATA I, II & III Mobile Rack Removable Hard Drive adapters, behind a hinged access door (red square, 2nd pic) on the front of the case.

By request from David, two ICY DOCK MB877SK-B Tray-less Removable Hard Drive adapters... to store his Scripts? hmmm

June 22, 2011 12:52:59 PM

The first of 2 lower half of the front bezel is finished. Next step is making the upper half and the compartment door covers.

I'll be sleeving the Sentry this Silverstone FP34S Premium 3.5inch Bay Card Reader & Front I/O combo module with our Black PSU and fan wires cable sleeve kit for everything. (8 mil PolyEthylene Terepthalate (PET) monofilament yarns)

June 23, 2011 4:52:32 PM

Finished the front Hot Swap bay compartment doors last night. These will be hinged with 1/8" rod. The 1/8" Opaque Red acrylic plates will attach to the back side of the door. Still need to make door handles.

June 24, 2011 3:55:39 PM

Here is where it's at currently, still need to make upper half of bezel, top panel, front grill, emblem and david's name plate.

June 25, 2011 2:02:42 PM

I finished the side panel inlays last night in between playing the Duke Nukem Forever demo... Now, I'm really looking forward to RAGE's release.

June 26, 2011 10:04:48 PM

Mike wanted the drive faces Stealthed. This mod is very straight forward. I'm using 1/8" diameter rod as spacer, but you can improvise this to whatever you wish for your stealth drive mod... and the aluminum faceplate I've cut is 1/8" thick.

PC Mod Ruler as fence spacer?!

1/8" diameter recessed hole.

cutting 1/8" diameter rod

A drop of ScotchWeld DP-190 epoxy, before inserting 1/8" rod

Apply 3 layers of Scotch 4010 double sided tape, for a tad of flex in the faceplate for contact to the eject switch.

paper fits in gap between switch and 1/8" rod

You now push in lower left corner of the faceplate to activate the Eject.

June 27, 2011 2:54:47 PM

As I traced out the badges to make by hand

Working on the front hot swap bay door handles and case badges..

to protect the paint finish under the door edge, I've applied Black automotive vinyl film

The blank spot is for david's signature plate....

June 27, 2011 7:51:13 PM

the Mill has a Belly ache....

June 28, 2011 7:38:03 PM

Door magnets were epoxied with ScotchWeld DP-190

June 29, 2011 3:48:46 PM

Here is the entire front bezel assembly. The Silverstone FP34S Premium 3.5inch Bay Card Reader & Front I/O combo module mounts at 45 degree angle in the top panel. It's held in place with m3 set screws, inserted into countersunk holes on each side of the top panel. David chose this model mainly for it's card reader and headphone jack. It's from performance-pcs here It will be mounted in the new top panel.

Upper portion of the front bezel attaches to the top panel with "key" style fasteners for 8/32 machine screws..

David's signature name plate..

June 30, 2011 3:52:36 PM

Stealthed Asus Blu-Ray drive installed.

behind the latched door, is 2x 3.5" HD Hot Swap bays

Used Round Modder's Mesh for the front grill, Modders Mesh

Strongest 2 part epoxy available, ScotchWeld DP-190.

The grill will be painted Matte Black.

July 6, 2011 7:43:34 PM

1st one arrived safely to Maximum PC Magazine's offices today... will ship 2nd with tribbles on Monday.. Here are final photos of 1st one before packing it.

July 8, 2011 7:12:49 PM

Always awesome work! What's next on the project list?
July 9, 2011 1:04:50 AM

need to finish my own build... ...I hope, lol Thank you bitterfun! (....hmmm picture looks familiar ;)  :hello: 
July 16, 2011 10:11:50 PM

Photo taken by Maximum PC for upcoming article on the build