Re: "Nazca" - Waterblock Concept
 

Alright. Looks like brass rod will be easiest and will allow me to get these dimensions for each cup.
http://www.captainslug.com/modding/mcp-block_99991.jpg
This should have the optimal nozzle-exit-size to distance-to-cup-base ratio based on what I've read.
But all of these dimensions are variable now that I can simply drill out the hole size I want in whatever rod size I want. The next rod size up is 3/64.

I would also like to thank everyone for their feedback. I'm learning way more than I had anticipated.

Re: "Nazca" - Waterblock Concept
 

This is a really neat design. I like how you have the water flowing from the inlet chamber to a 360deg outlet chamber. Very clever. Can't wait to see an actual design. PM me if you want good 3d rendered previz.

Re: "Nazca" - Waterblock Concept
 

Much easier with a rotary table.
They aren't that expensive (think Chinese) and, unless you are magic, your plan on drilling/fixturing/refixturing/more drilling, etc. is not gonna work, especially at the sizes/tolerances we're talking about here.
Seriously....rotary table.

Re: "Nazca" - Waterblock Concept
 

The channel bends and pits are the same bit size and will most likely be done using a programmable mill to save time and effort. Then the lathe work begins, and after that I'll mill the channels.

The mounting holes could be done with a bridgeport or pre-drilled to a smaller size with the programmable mill.

Re: "Nazca" - Waterblock Concept
 

Thread revival!
I'm not sure if I really want to experiment with jet impingement right now and I'm being a cheapskate so I'm trying to revise my design minus the nozzles and pits.

So I'm just going to go with a slightly simplified version that I can make from a 2x2x0.1875" copper scrap. Fin height is 3.16mm and base thickness is 1.5mm (blame inches).
http://www.captainslug.com/modding/nazca-1.jpg

I'm going to be doing all the work myself on a manual mill so I think I'm going to start with something relatively simple. I'll be able to do the 45-degree channels by simply making a mounting block that the base bolts onto. Both barbs will be 3/8" NPT x 1/2"ID tubing.
I have the tools, the time, and the materials. I just need to get back to wrapping my head around this since I've been away for a few months.

Re: "Nazca" - Waterblock Concept
 

looks fun, watch out for the top cover leakage, otherwise its pretty cool

Re: "Nazca" - Waterblock Concept
 

Here's the coverage on a 1.25" IHS
http://www.captainslug.com/modding/nazca-2.jpg
I'll be using a 1-1/2" ID 1-5/8" OD Red-Orange Silicone O-Ring

Re: "Nazca" - Waterblock Concept
 

I've decided to make this a little bit easier on myself by simplifying the machining of the block a little. The new design is a sandwhich of three parts that collectively will be easier to make. It may also alleviate the outlet concerns of the previous revisions,
http://www.captainslug.com/modding/nazca-3.jpg
http://www.captainslug.com/modding/nazca-4.jpg
The plate in the middle will be solvent-adhered to the thick top piece.

Re: "Nazca" - Waterblock Concept
 

nice design but i liked the older revisions more, just try it on a cnc then its no problem with that many bends;).
performance should be on a level with top waterblocks ala rbx/tdx or white water.

it remembers me of a little bit similar block which i did some time ago (the block on the right). Its sandblastet and polished. channels are 8x 1mm*2,5mm
http://davidzo.cooling-store.de/k5/PICT1182k.jpg

Re: "Nazca" - Waterblock Concept
 

I don't have access to CNC. All of the tooling will be done with manual equipment. I've been keeping that in mind with all of my designs so they're all possible to make with manual equipment. The newest revision could work with the older base design, but I'm unsure about being able to add the channel bends with a manual mill.
Sure this would all be much easier with CNC equipment, but I don't know anyone who would help me out for free with that. I already have the materials and free access to the manual mill.

And I haven't mentioned this here yet but I'm also working on my own 1/2" ID 3/4" OD compression fittings.
http://www.captainslug.com/modding/mk6_90.jpg
http://www.captainslug.com/modding/mk6_9996.jpg
I'll do some more thinking about nozzle and channel refinements.

Re: "Nazca" - Waterblock Concept
 

Improvement?
http://www.captainslug.com/modding/nazca-5.jpg
My pump can handle the restriction if I can handle the machining of the base.

Re: "Nazca" - Waterblock Concept
 

why are you making compression fittings on your own? I thought there is a huge selection on the market of those.

The nozzle looks nice, but i believe a nozzle with only holes would perform better. I have a round chamber in the top of the block below and tried different round shaped nozzleplates. The nozzle with only holes was a little better than a nozzle whith slits like a star.

In all i think the block will still be horrible to manufacture with a manual mill, but i would love to see you try it and make it like it looks as a rendering, i would like it even better if it was one of the earlier revisions (latest on page1 looks good).

I have a very small CNC-mill and recently made a version of my K5 which you see in Post #39 with 2mm channels witheout bends instead of the highly restrictive 1mm ones. If you are interested i will show you pics and specs when i am finished with this two blocks. If I had some more free time i would offer you to mill the cooler on my cnc, but that is curently impossible and would also be very complex to redo your drawings in my proprietary CAD/CAM software that i could draw one or two new designs in that time.

Re: "Nazca" - Waterblock Concept
 

My whole loop will be using 1/2" ID 3/4" OD tubing which is not a size that compression fittings are offered for. So I'm making my own out of delrin.

I'm still hedging on whether or not to bother with jet impringement using nozzles and cups but based on your advice I will go with a drilled nozzle pattern rather than the star pattern. The star pattern was solving a machining issue that the new design no longer has.

The only person I've talked to in the states about CNC work is JFettig, and I don't know what software he uses. I'm using Alibre Xpress because it's what the machine shop I go to uses and it's very easy to work with.

Re: "Nazca" - Waterblock Concept
 

The nozzle plate is done.
http://www.captainslug.com/modding/nazca-6.jpg
http://www.captainslug.com/modding/nazca-7.jpg

Re: "Nazca" - Waterblock Concept
 

Hey, nicely done. Compression fittings look interesting as well - do they work as intended?

Re: "Nazca" - Waterblock Concept
 

Actually I screwed up the compression fittings. I couldn't get a working thread on them with the die blocks. So if I want to make them the way I intended them to be I'd have to start over again.
After some fiddling about yesterday I discovered that the collar nuts that I hadn't finished making for the compression fittings make some strangely effective tubing clamps.
http://www.captainslug.com/modding/mk6_9998.jpg
You slip the collar nut around the fitting, slide the tubing onto the fitting, then pull the collar nut onto the tubing like so.
http://www.captainslug.com/modding/mk6_9999.jpg
What I end up with is basically like chinese hand-cuffs. The harder I pull on the tubing, the harder the collar nut clamps the tubing to the fitting. The tubing cannot be pulled off the fitting with the collar inplace because the inner diameter of the collar nut fits the outside of the tubing so precisely that the tubing can't get over the lip on the barb. To unclamp the tubing you just push the collar nut away from the tubing.

I've accidentally made a backwards compression fitting. I want to do some leak testing with these, the pump, and one block later.
If I want to attempt making compression fittings again I'll have to use the lathe to add the thread to the fittings rather than trying to do it with the die blocks.

Re: "Nazca" - Waterblock Concept
 

nice invention. if that works good, why not use it, it sounds very practical

nozzleplate looks good. a picture from the backside would be interesting. why is there a hole in the middle?

Re: "Nazca" - Waterblock Concept
 

The 4 holes in the exact center were a little too fragile. So the center won't have nozzles unless I want to make a new nozzle plate out of brass or delrin. I don't think the center lacking 4 nozzles will really effect anything though so I'm not worried about it.

Re: "Nazca" - Waterblock Concept
 

ah, thats it. I think it will have a noticable negative impact on performance.
There is a guy in germany who made a lot of tests about coolers with nozzles. he tried different nozzle sizes too. In his tests one bigger nozzle in the middle was always a very bad thing and did affect performance a lot. It is a little different setup so it can't be translated to every nozzlesetup, but i think in this case it is agood guess that the bigger nozzle in the middle will affect performance negatively.
Read about it here (german translated with google): http://translate.google.com/translat...language_tools

Re: "Nazca" - Waterblock Concept
 

Alright. Once I get some more label paper I'll make a new one.

Re: "Nazca" - Waterblock Concept
 

i really like the compression cuffs... might look into making some of my own =p. I have a CNC you might be able to use for machining this all. Only problem is I don't have one for metal at the moment, the controller went crazy and it's in for repars, should be back this week. If you could send me some cad drawings, i could machine it out and test it for you. If you can't get a cad drawing, a stereo lithography file will be ok as well, i just can't modify it without your help.

are the nozzles on the mid plate chamfered or actually rounded edges? I'm thinking about doing some completely rounded ones, it should be interesting. Physics teacher said it would have less turbulence entering the jet, and hence more flow? I'm debating methods of cutting this rounded nozzle edge. Anyone with machining experience know?

Re: "Nazca" - Waterblock Concept
 

You could always try to use a very fine file and a steady hand to round them.

Re: "Nazca" - Waterblock Concept
 

The "compression cuffs" are REALLY easy to make out of solid round bar if you use a decent manual lathe to taper the inside of whatever size hole you drill for the ID. Any material will do, I used 1-1/8" OD black delrin but could have just as easily made them out of aluminum, brass, nylon, or even PVC considering how thick the pieces ended up being. I need to make a few more so the next ones may be made from scrap aluminum.

I have the block design in Alibre Xpress format only at the moment. The free version can't export in other file types, but I could probably take it on a disk to the machine shop and convert it to another format that you can use if you want to make a testing copy.

The nozzles have a very slight countersunk edge on both sides due to burr removal. The outlets are countersunk by hand using an X-acto knife. If a rounded bevel edge were desired I think the easiest way would be to flame-polish the plastic nozzle plate which would do all the work for you. Otherwise you would need a custom bit.

I just finished the replacement nozzle plate which has the 4 holes the first one was missing.
I might experiment with flame polishing on the "messed up" nozzle plate.

Re: "Nazca" - Waterblock Concept
 

This is very interesting indeed. I think i'll be drawing a few of those compression cuffs for cad, just because every part of my system needs the cuffs. How much space are you leaving for the rubber tubing between cuff and barb? and how thick is the tubing? I'll be making mine out of metal, and I don't want to be slicing through the tubing or anything xD.

I'll just got the metal CNC controller back from the mfg, so i'll be using that very soon.

oh yeah, and for the rounded edges, a CNC could technically do that with a bore end mill. It basically is like a ball nose cutter. my biggest problem is just drawing it in proDesktop =p. I'm still very unfamiliar with the software, and i'll be taking time to learn it properly.

Re: "Nazca" - Waterblock Concept
 

The tubing I'm using is 1/2" ID 3/4" OD. The cuff dimensions that I'm making are 1-1/8" OD, 3/4" ID at one end, and 25/32 (roughly 0.81") at the other. They're only meant to work with single-barbed or lipped fittings but you can make them for any size. You simply want the ID at one end to match or be a little bit smaller than the OD of your tubing. Then in the middle or one third of the way through the inside you want a gradual transition from the neutral tubing OD to the OD of the tubing that's wrapped over the thickest point on the barb.

I just made one out of brass.
http://www.captainslug.com/modding/mk6_99997.jpg

I broke my only 1/16th milling bit right as I started working on the block. Luckily nothing is messed up except the bit so i just have to wait for a replacement. If you can, I would be very very grateful if you could make just the base. It's going to be hell to make with manual equipment. I'll look into proDesktop to see if I can make the CAD file for you.

Edit: Just did a leak test with the fillport and the compression cuff and YAY! They both work (as in they don't leak when subjected to 30PSI).
:D

Re: "Nazca" - Waterblock Concept
 

Halfway through milling the base of the CPU waterblock. Each straight channel length requires three passes (.05" deep cut per pass).
http://www.captainslug.com/modding/mk6_999991.jpg
5 hours of manual work so far and 5 or 6 more to go which I'll be able to do on Tuesday. Then I just need to make the top.

Slooooooow going but I've proved to myself that I can do it with the amount of patience that I have. Almost screwed things up because I hadn't thought to put a water trap on the air compressor line so it's excessive drooling of moisture which is a result of the recent rainfall amost killed my template label.

I'll get a better macro shot once the base is done and cleaned.

Re: "Nazca" - Waterblock Concept
 

Looking great. Slaving over a mill for such a long time while remaining both persistant and delicately cautious is no small feat. And could that be Tygon R3400 above? A man with taste!

Methinks it's time for me to spend a few bucks on my own project. Yes indeed.

Re: "Nazca" - Waterblock Concept
 

Good eye. I'm using 1/2" ID 3/4" OD Tygon R3400 for this machine. And since nobody offers anti-kink product for that size of tubing I'm using some AR15 action springs to support the tighter bends in my loop.

Re: "Nazca" - Waterblock Concept
 

"AR15 action springs"

Military surplus? Where abouts in Va did you get those?

Re: "Nazca" - Waterblock Concept
 

Nice work so far. Will be interesting to see how the inlet and outlet will work out. Mostly space wise in between connectors. Make sure to leave enough room for the the thickness of both hoses and hose clamps.