DIY eGPU Case Proposal (Thunderbolt)

[redback79]

Hello everybody! This is my first post here but I have been following the DIY eGPU thread in this forum for quite a while now. Epic!

I would like to share with you a proposal for a DIY eGPU chassis I was working on in my spare time (see images attached). Hoping that hwtools is going to provide the world sooner or later with all the necessary parts for a Thunderbolt eGPU, I fired up my CAD program and got started. It does look good for Thunderbolt in 2012 I guess. After all the last years Mac-only crap Thunderbolt might make its way into PC systems soon... and along with it new DIY parts from "hwtools & friends" I hope :-)

A few assumptions first
If hwtools applies the same logic as I do, they would like to keep their existing hardware and make it compatible to Thunderbolt. A way to do that would be a small module consisting of a Thunderbolt chipset, two PCIe cable connectors and two Thunderbolt connectors (from my humble understanding of the matter). This module could be hooked up to the existing PCIe expansion card via two PCIe cables and... well... make my dreams come true :-) Such a module would provide more flexibility for all their customers by giving them great freedom where to place their Thunderbolt ports. Of corse another way to argue would be that hwtools wants to sell brand new stuff for lots of money and therefore develops a completely new expansion card - but even then - the overall format/size would likely not change much from what is existing. Let's see what they come up with (if at all)... Basically I am just guessing here.

Case study ;-)
But lets get started with the case. As a basis I took the existing hwtools PCIe expansion card and a GTX570 to build the case around. I decided that it should be placed on the desk and stay there. It should, however, survive an occasional transport. Ah and yes, worth mentioning that I own a 2011 MacBook Air along with a Thunderbolt display. Display and laptop are sleek pieces of hardware! So you DIY case better blend in nicely! :-D Another thing worth mentioning: Because of the displays connectivity, Ethernet, USB or Firewire are not an issue for me. To round it up, all I want is well dressed, decent graphic power!

with_cover.jpg

with_cover_2.jpg

Looking at the case from the front, the cover is perforated on the left side for GPU airflow and features two thunderbolt connections on the right side. Since I would like to place the case to the left of my screen and laptop with the GPU fan pointing away from me (might reduce the noise a bit) it seemed to be a good spot for the Thunderbolt connectors.

cover_removed_01.jpg

cover_removed_02.jpg

Both main parts (base and cover) would be sleekest if made of sheet metal (laser/water/CNC-cut, and maybe even professionally pre-bent). But that is likely getting expensive - especially the cover with all its holes. Not quite as chic but cheaper would be antistatic acrylic glass instead of metal. As long as the parts are treated with care the case would still look high quality. One would not even have to let go of the metal finish for the base if it was nicely spray painted. Unless one is physically touching the part, it's hardly noticeable that it is not made of actual metal... However, I would like to be "honest" and prefer to show the material stuff is made of. It will be a matter of price.

explosion.jpg

The exploded case visualisation should give you a good overview of all the other necessary parts such as a thin sheet metal part to cover the sides of the GPU at the back, a power connector (for an external power adapter of approx. 350-400W ;-) ) a power switch (it could even be an original PowerMac Switch which I found on welovemacs.com) and a bunch of screws and distance holders. Of more structural nature are the two metal rods connecting the open ends of the base part. They are meant add to the overall rigidness.

...why do I share this?
Let's face it: I have no experience with eGPU or DIY electronics just yet. I am quite confident about my planing and handicraft capabilities though. With your knowledge and my hands I might feel confident enough to actually go for it.
But there is also another reason. By the time all necessary parts for a Thunderbolt eGPU are available I want to adjust the case accordingly and build a prototype... and if some of you should be interested, I want to make it open source, providing all details necessary to rebuild it (something like a downloadable package with technical drawings, shop list for parts and of course including the files for the lasercut guy near you...). I never did something like this before, but some sort of community based project could emerge from this!

Hope you are excited as I am! Cant wait for your feedback!!!

Cheers
redback79

[SimoxTav]

Originally Posted by redback79

...cut...

GREAT work!
One quick question for you then! I'm working on an enclosure too (but for the upcoming new PE4H only + an ATX PSU). Are the screws in the right positions? I've looked at the PE4L and i found where the holes are, but on PE4H i had some issue finding them. My design is far behind yours (starting from the point i'm not a designer at all :P), attached a screen (with a GTX560 model inside).

Just 2 things i noticed:

1- the cable from the "PE4H" to the TB PCB, probably you have to consider the curve of the cable so adjust a bit the width of the case (i hope they put the connectors on the short side)

2- GPU --> PSU cables (through 6-8pins cables). Beware that not all the cards has the connectors in front of the card, some has them above, so make room for them for a multipurpose installation. Furthermore, TB can bring only 10W of power (at least now), so i haven't understood where those 6-8 pins cables are coming out to the PSU.

[redback79]

Hello SimoxTA,

Nice case you are working on there! Including an ATX PSU is definitely another way to go. All in one case. NICE! Did you ever look at a 1U server PSU's? They are different in format (and maybe a bit more expensive) but you could shrink the case significantly.

Thanks for the input about the power connectors! I will have to give the card a bit more head room. First entry in my change log :-) Also the PCIe cables might need more room. Although from what I have seen on pictures on hwtools website (PE4H (PCIe passive adapter ver2.4)) the connectors seem quite tiny. I would certainly order all the parts first, measure their dimensions, wire everything see how much space is actually needed before cutting the first parts.

As for the PE4H screw holes visit the link above. At the button of the page are detailed PDF's for download. They don't contain the a lot of measurements but a clearly defined width and length of the card. I imported the PDF into Illustrator, resized it to a 1:1 scale and measured the centers of the holes. Hope I got you right!?

redback

PS. One more question: What material are you planning to use for your case?

[SimoxTav]

Originally Posted by redback79

Hello SimoxTA,

Nice case you are working on there! Including an ATX PSU is definitely another way to go. All in one case. NICE! Did you ever look at a 1U server PSU's? They are different in format (and maybe a bit more expensive) but you could shrink the case significantly.

Thanks for the input about the power connectors! I will have to give the card a bit more head room. First entry in my change log :-) Also the PCIe cables might need more room. Although from what I have seen on pictures on hwtools website (PE4H (PCIe passive adapter ver2.4)) the connectors seem quite tiny. I would certainly order all the parts first, measure their dimensions, wire everything see how much space is actually needed before cutting the first parts.

As for the PE4H screw holes visit the link above. At the button of the page are detailed PDF's for download. They don't contain the a lot of measurements but a clearly defined width and length of the card. I imported the PDF into Illustrator, resized it to a 1:1 scale and measured the centers of the holes. Hope I got you right!?

redback

PS. One more question: What material are you planning to use for your case?

Thanks for the suggestions about the screw holes, i'll try to handle the thing with similar tools ^_^ (not enough money for the Adobe suite :P) ! I've also made a model with a 1U PSU (this one exactly) that has a reasonable price, but my main worries are about the loudness of the PSU (4cm fans have to spin faster to keep the the temperature low), and the lack of a forth molex, that brings the need to have one of the two 6pin connectors on a 1-1 adapter with the molex (while usually it's a 2 molex to 1 6pins to have less current on the cable). I'm also studying about an adapter that can take advantage from a flexible PCIe riser to rotate the card and the PE4H and keep both horizontally.

About the material probably it will be polycarbon, because i have people in my company able to work it and it should cost less than making it in aluminum/metal (with the risk of reverb of the fan). From what i know, the raw material should cost about 5-6€ per Kg, so the biggest cost is to model it.

[redback79]

Good point! Didn't think about the noise level of a server PSU. After looking at some of them more closely I also get the connector problem...

Speaking of PSU's. I want to get the power necessary from an external power brick but didn't look into ways on how to distribute it within the case itself yet. Could turn out to be a tricky task.

An alternative to the current design could be: A 6- and a 8pin extension cable plugged to the graphics card and a "Floppy" extension cable plugged to the PCI extension card which are both routed trough the case to be connected to a normal ATX PSU. Not really a sleek solution considering that I would have another case lying around on my desk with cables (and a switch to turn it on) hanging from it. :-(

I'm happy about suggestions? :-)

[SimoxTav]

Originally Posted by redback79

Good point! Didn't think about the noise level of a server PSU. After looking at some of them more closely I also get the connector problem...

Speaking of PSU's. I want to get the power necessary from an external power brick but didn't look into ways on how to distribute it within the case itself yet. Could turn out to be a tricky task.

An alternative to the current design could be: A 6- and a 8pin extension cable plugged to the graphics card and a "Floppy" extension cable plugged to the PCI extension card which are both routed trough the case to be connected to a normal ATX PSU. Not really a sleek solution considering that I would have another case lying around on my desk with cables (and a switch to turn it on) hanging from it. :-(

I'm happy about suggestions? :-)

Using an Xbox 360 PSU like someone already did could be one solution, but i don't think i would be able to "cannibalize" it

Anyway, Villagetronic use a brick that can handle up to 225W, so i think that they could be rare but not "non-existant". Another solution (but i have to check it with colleagues) is to take an open frame PSU with multiple output, like the one that Meanwell sells.

[nando4]

Firstly, a great thread there redback79. The enclosure design you propose is a piece of artwork

Originally Posted by SimoxTa

Anyway, Villagetronic use a brick that can handle up to 225W, so i think that they could be rare but not "non-existant".

Villagetronic use a two AC adapters to achieve 225W: a large 150W one and a smaller 75W one.

Masaharu Adachi (Bplus) replied with the following after being pointed to this thread:

> There are folks already pre-planning how they are going to build a case
> to house your PE5H Thunderbolt adapter:http://forum.notebookreview.com/gami...ml#post8142428
> I expect this thread will develop further. As long as the PE5H is relatively affordable
> then it may well be the DIY enclosure thread will engage folks wanting the latest
> and greatest in design.

Thank you for the information. It's pretty nice enclosure for GPU boards. We would like to have our enclosure design as simple as possible, for lower cost and easy maintenance.

> If you can provide the PE5H chassis dimensions, the I/O plugs being
> used (on/off and power) then I could post those details for others
> to start their design work from. You can see the poster intends
> to have a 300-400W external PSU to drive it.

We would like to support not only AC adapter but also external ATX PSU for larger GPU. Also, LEDs for status check and air flow are very important.

[redback79]

Thanks nando4

First a compliment from YOU! and then a the direction to this thread send straight to the executive floor! :-D

Can't wait for more info on the PE5H adapter! I definitely see potential here for more "looks orientated" case builders. I know many people out there that would die getting their hands dirty building a case. It's great fun and as a nice side-effect they get the kick-a** modeling and rendering power to their laptops (or iMac's) they were always dreaming of. Also consider that most design or engineering students have all kinds of nice machinery waiting to be used somewhere downstairs in their faculty. I bet some would soon rapid prototype the whole thing... or mill it out of a solid block of aluminum. :-)

From my point of view the choice between two new DIY Thunderbolt eGPU kits would be ultimate: One allowing for a sleek desktop case with an external power source (300-400W) including the necessary power brick(s) and another one for the less space savvy and enthusiasts with the possibility to connect an ATX PSU inside the case (400W+).

[nando4]

Originally Posted by redback79

First a compliment from YOU! and then a the direction to this thread send straight to the executive floor! :-D

Had to be done. design appeals more than anything I've seen from the commercial manufacturers, eg: Villagetronic, Magma. So of course, I alerted bplus to this thread so as to:

1. hasten production of the PE5 product (Thunderbolt) so you'd have the electronic board to play with
2. consider how the boards will integrated with their own and/or third party enclosures

Originally Posted by redback79

Also consider that most design or engineering students have all kinds of nice machinery waiting to be used somewhere downstairs in their faculty. I bet some would soon rapid prototype the whole thing... or mill it out of a solid block of aluminum. :-)

Saw them use this sort of tech on Mythbusters 'Killer Surfboard' episode. The crew did a CAD design of their board and then printed (milled) a small surfboard for aerodynamic testing. Was very impressed at how easy it was.

Means passionate artists/designers can unleash their creative potential. Maybe we'll have a gallery of DIY eGPU enclosures to choose from in the future?

[@nthony]

this is an awesome thread, I've seen a lot about eGPU and power supply, but this is the first considering standardized approaches to casing. keep it up!