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It is an elegant solution, though I'm planning something a bit different. I plan to make a single power cord going to my 'kill relay' with the pump hard wired to the output of the relay. Unless I have a reason that I must, I don't want to open or mod the PSU if I don't have to, as I prefer to keep the warranty intact. I'm using a PCP&C unit that's expensive enough I want to keep it under warranty.
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It's hard sometimes to get over a point in text sometimes, I wasn't suggesting you copy my system of preventing the pump not being plugged in, more just highlighting the types of things that are more likely to cause disasters, (assuming the design and application of the system is solid), before one gets involved in many overly complex protection systems. I believe user error causes most of these things. I once refilled my system and stopped when I heard trickling water. I'd forgotten to plug in one of the PSU fetsos at some point when I'd had the set-up apart. It was in the fitting but not tight. The result was water all over the mobo, vga card & sound card. As I had unplugged the PSU and de-powered the system before working on it, this was only a minor annoyance that ment I had to spend half an hour with a hairdryer and an blow gun before I could get back to where I was previously.
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I guess I'll experiment a bit... I'll be using either a propane torch or an oxy-acetylene rig, so I may be able to do more heat than you get with your torch. (I've even wondered about brass brazing, but am inclined against it overall.)
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Using an oxy-acetylene rig can prove hard as the copper will tarnish with the heat quicker making it more difficult to get the solder to flow and take. Also heat warpage of the copper can be an issue if you get it too hot.
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I was thinking of soldering in my barbs because I'm not sure about how well the threads would hold in my top (only 1/4" thick). Additionally, I plan to trim some or all of the thread that sticks through the inside of the top so it doesn't obstruct the coolant flow. I don't want to take the barb out after I do that because of possible problems getting it back in, and if I cut it on an angle, aligning it.
I noticed your mentions that you had to deal with the top drifting out of position when soldering the block up, I was thinking that if I put the barbs in place and trimmed them ahead of time, then I could use them as locating pins when doing the solder up, and just flow some solder into the threads while things were still hot.
I am surprised that you consider teflon tape leak prone however - We have teflon taped joints in the plumbing all over the house, and no leaks despite the 110psi mains pressure we were getting. (I agree it can be ugly though)
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It's unlikely if done well but I've had weeps and minor leaks from household plumbing fittings using PTFE tape in a no pressurised UK style system. As said in PC water-cooling zero leaks/weeps are the order of the day.
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The stuff at the local store seems pretty flexible, though I haven't compared it to Tygon. I may see if I can find some Tygon locally to see if I think it's enough better to justify switching to it. I might also do a mixed set-up with Tygon for the block plumbing and braided elsewhere - I know I'll be using at least 3-4 different sizes of tubing in my set-up so it wouldn't be difficult. I do need to worry some about my block mountings since I have to do a clip-on mount (my mobo won't have the holes for a bolt-on mount, one of it's few flaws IMHO) I'm going to make a 3 lug clip out of 304 stainless, but still...
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I'd send you a small piece of tygon to try if you were not on the other side of the pond, however a foot of it wont cost much if you can find a local supplier. I used a socket lug waterblock when I first started over two years ago, and it was a bit of a concern but the choice of blocks was very limited back then. Now I would never put any mobo on my shopping list if it didn't come with socket holes, for waterblock retention.
Just for interest I did this basic schematic in ms paint the other day that clearly shows how my system flow is configured.
