DIY Corsair Case Mod: Corsair 350 / 900 Front Air Intake Grill

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech9f.jpg

 

This is DIY Case Mod Guide for modifying your Corsair 350 & 900D Front Air Intake Grill to help improve airflow to your Liquid or Aircooled PC system

 

Tools & Supplies:

 

Modder's Mesh, Round Sheet,http://mnpctech.com/case-mods-gaming-pc-liquid-modding-custom-computer-mnpctech-overclock-cooling-fan-grills/modders-mesh-perforated-aluminum-steel-honeycomb-grill-intake-front-fan-slotted-diamond-round-hex/modders-mesh.html

 

http://mnpctech.com/images/thumbnails/280/210/detailed/1/mesh5_09fg-5q.32.jpg

 

In Order of Usage

 

1. Ruler or Measuring Combination Square,

http://www.amazon.com/Empire-Level-E250-Professional-Combination/dp/B000ETUNEU/ref=sr_1_2?s=hi&ie=UTF8&qid=1371561237&sr=1-2&keywords=measuring+square

 

*2. Pen & Black Marker,

http://www.amazon.com/Sharpie-30001EA-Permanent-Marker-Black-SAN30001EA/dp/B00584PWWO/ref=sr_1_2?s=hi&ie=UTF8&qid=1371565029&sr=1-2&keywords=sharpie+black

 

3. Phillips Screw Driver,

http://www.amazon.com/STANLEY-TOOLS-68-012-All-in-One-Screwdriver/dp/B00009V431/ref=sr_1_1?s=hi&ie=UTF8&qid=1371561308&sr=1-1&keywords=phillips+screwdriver

 

4. 3" Painter's Masking Tape,

http://mnpctech.com/case-mods-gaming-pc-liquid-modding-custom-computer-mnpctech-overclock-cooling-fan-grills/3m-scotch-233-performance-green-masking-tape-roll.html

 

5. Safety Glasses,

http://www.mnpctech.com/Safetyglasses.html

 

6. Rotary Tool,

http://www.amazon.com/Black-Decker-RTX-6-3-Speed-Accessories/dp/B0001GUDRI

 

7. Rotary*1.5" Cutting Wheel,http://www.mnpctech.com/DremelDisc.html

 

8. Jigsaw Power Tool,

http://www.amazon.com/s/ref=nb_sb_noss?url=node%3D552934&field-keywords=jigsaw

 

9. 18 TPI bi-metal Jigsaw blade,

http://www.amazon.com/Bosch-T118EF-Bi-Metal-Shank-Jigsaw/dp/B000628CZ2/ref=sr_1_2?s=hi&ie=UTF8&qid=1371558431&sr=1-2&keywords=jigsaw+18+tpi+blade

 

10. Hand File,

http://www.amazon.com/Nicholson-06601-8-Inch-Handy-File/dp/B00002N7RN/ref=sr_1_6?s=hi&ie=UTF8&qid=1371558465&sr=1-6&keywords=hand+file

 

11. Blue Painter's Tape, 1" wide,

http://www.amazon.com/ScotchBlue-Painters-Multi-Surface-70-Inch-60-Yard/dp/B00004Z4BB/ref=sr_1_1?s=hi&ie=UTF8&qid=1371561766&sr=1-1&keywords=blue+painters+tape

 

12. ScotchWeld DP-190,

http://www.amazon.com/3M-Scotch-Weld-Adhesive-DP190-Translucent/dp/B0074N8N3W/ref=sr_1_1?s=hi&ie=UTF8&qid=1371558594&sr=1-1&keywords=scotchweld+dp190

 

(Optional) 3M Applicator Gun EPX Plus II and mixing tip, for ScotchWeld,

http://www.amazon.com/3M-Scotch-Weld-EPX-Plus-Applicator/dp/B001ANXYF4/ref=sr_1_fkmr0_3?s=hi&ie=UTF8&qid=1371558713&sr=1-3-fkmr0&keywords=scotchweld+dp190+applicator

 

13. Disposable Latex Rubber Glove, (for applying DP190 into mesh)*http://www.amazon.com/Stanley-Helpers-Disposable-Lightly-Powdered/dp/B000DILNJ6/ref=sr_1_7?s=hi&ie=UTF8&qid=1371558808&sr=1-7&keywords=disposable+rubber+gloves

 

14. Cloth or Rag,

http://www.amazon.com/Essentials-14-Inch-17-Inch-24-Pack-WT24/dp/B000ICRJ4A/ref=sr_1_1?s=hi&ie=UTF8&qid=1371565083&sr=1-1&keywords=cloth+rag+shop

 

15. Modeler or Xacto Knife,

http://www.amazon.com/Xacto-X3601-Precision-Knife-Safety/dp/B00009R8JZ/ref=sr_1_4?s=hi&ie=UTF8&qid=1371558896&sr=1-4&keywords=xacto+knife

 

16. Red Scotchbrite,http://www.mnpctech.com/3m_scotchbrite_pads_red.html

 

17. Filtered Respirator Mask,

http://www.amazon.com/3M-Low-Maintenance-Half-Mask-Respirator-Assembly/dp/B00004Z4EB/ref=sr_1_1?s=hi&ie=UTF8&qid=1371558931&sr=1-1&keywords=3m+filtered+respirator+mask

 

18. SEM Self Etching Primer, Black,

http://www.amazon.com/SEM-SEM39673-Etching-Primer--Aerosol/dp/B000PKZ3IY/ref=sr_1_cc_1?s=aps&ie=UTF8&qid=1371558960&sr=1-1-catcorr&keywords=sem+self+etching+black

 

19. Krylon "Rust Tough" Semi-Flat Black Enamel (or Plastikote "Engine" Enamel),*]http://www.amazon.com/Krylon-RTA9203-Semi-Flat-Preventive-Enamel/dp/B000RMTDAE/ref=sr_1_1?s=hi&ie=UTF8&qid=1371559001&sr=1-1&keywords=krylon+rust+tough+black+flat

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech_diy1.jpg

 

Corsair Factory Front Bezel Plate.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech_diy2.jpg

 

Corsair gives you 3/16" gap around the plate from the factory for airflow. This modification will be huge improvement for cooling your system.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech_diy3.jpg

 

The front plate pulls off without any effort. It's removed for accessing and cleaning the Corsair 900D's three 120mm front cooling fans and filter.

 

You have option to remove the Four plastic mounting pegs, or leave them on throughout the entire modification process. It's your choice! The pegs are fastened on with Phillips head screws.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech_diy4.jpg

 

The best tape is 3M Scotch 233+ Green tape

 

3M Scotch Green 233+ masking tape is used by Automotive Paint Professionals. It's highly conformable to curved surfaces on both metal and plastic. It has good adhesion in a large range of weather conditions. It will peel off without leaving any sticky residue. Most Auto Body Supply Stores should be stocking this tape. It's also readily available online. 3M Scotch *233+ tape has a premium price compared to other tapes, but it performs the best*

 

 

 

The 900D front plate is made from Anodized Black aluminum. We're going to retain this factory finish.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech1.jpg

 

Use Measuring Square or Ruler, to measure out 1" framed border around the Corsair's 900D plate

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech2.jpg

 

Put on your Safety Glasses, before using any Power Tools.

 

Using Rotary Tool with 1.5" Cutting Wheel, to make four incision cuts on each of the four sides. This step is necessary, before you can use the Jigsaw to remove the center.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech3.jpg

 

Using Jigsaw with 18 TPI bi-metal cutting blade to remove the center of the plate you measured out.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech4.jpg

 

The center section of the plate has been cut.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech5.jpg

 

Using Hand File to fix and clean the jagged edges of the cut out. You'll want to remove the masking tape, so you can better view your progress with the file.

 

Modder's Mesh, Round,http://mnpctech.com/case-mods-gaming-pc-liquid-modding-custom-computer-mnpctech-overclock-cooling-fan-grills/modders-mesh-perforated-aluminum-steel-honeycomb-grill-intake-front-fan-slotted-diamond-round-hex/modders-mesh.html

 

http://mnpctech.com/images/thumbnails/280/210/detailed/1/mesh5_09fg-5q.32.jpg

 

I'm attaching Round Modder's Mesh[/b] to the backside of the front plate.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech6.jpg

 

Measure out piece of Round Modder's Mesh to 15" LONG by 7.25" WIDE.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech6a.jpg

 

Use Tin Snip or Metal Cutting Shear to cut the Round Modder's Mesh

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech7.jpg

 

Attach the Round Modder's Mesh to backside of the front plate with Spring Loaded clamps. You can also use small C-clamps.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech8.jpg

 

Apply Painter's Tape around the edge of the mesh on back on front side of the plate. This is to help prevent any ScotchWeld DP-190 epoxy from running off the Modders Mesh onto the plate.

 

http://www.mnpctech.3dpixelnet.com/picture_library/CPUHood1lbwb.jpg[/img

 

I'll be using ScotchWeld DP-190[/font]for*attaching the Round Modder's Mesh to backside of the plate.

 

You'll need to wear Latex gloves, when using the ScotchWeld DP-190.*You can manually push the two cylinders of Epoxy in DP-190 Cartridge onto a piece of cardboard. Then mix the two epoxies together with a long wood nail or pop-rivet.*Otherwise*3M sells a ScotchWeld Applicator Gun, for $70.00 with spiral mixing tip, for ScotchWeld

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech9.jpg

 

Wearing latex glove, use your finger to evenly smear the ScotchWeld DP-190 epoxy into the perforations of the Round Modder's Mesh

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech9a.jpg

 

Use a cloth or rag, to wipe off any epoxy run-off from the sides of the plate

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech9b.jpg

 

Wear filtered Respirator Mesh before applying any paint.

 

Apply paint in well ventilated area, preferably outdoors with temperature around 72F

 

I'm painting the backside of the mesh first, starting with coat of SEM brand self etching primer. Allow it to cure for one hour before applying Krylon "Rust Tough" "Semi-Flat" Black *paint. Allow "Rust Tough" to cure for 24 hours.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech9c.jpg

 

Mask off the front frame, and repeat same steps for painting the front of the plate.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech9d.jpg

 

After 24 hours, remove the tape.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech9e.jpg

 

Close up of the bezel plate.

 

http://www.mnpctech.3dpixelnet.com/picture_library/900d_front_grill_case_gaming_pc_mod_mnpctech9g.jpg

 

Step back and admire your work!

 

You can use this technique to attach Modder's Mesh to create cooling vents in other panels.

 

Please share any questions or comments!

Excellent tutorial! I've suggested doing something similar for the 750D (without the details and illustrations). I would suggest one thing, though. Where you said to put painters tape around the modders' mesh to keep the epoxy off the panel, I would also put the tape on the mesh itself to make sure no epoxy would get where it wasn't wanted and would show from the front.

Good tip! Thank you LF :sunglasse

we played around with different test pieces until we nailed down the right steps to mill the factory plate without splintering or cracking the plastic panel on the back. Here is the result with 350D version, and next will be 750D, then 900D, once I find cheaper resource for bulk ordering the factory plates, and listing them here,*https://mnpctech.com/mnpctech-clear-case-pc-panels/corsair-350d-plate/

 

CNC milled 1/4" diameter ventilation holes into a *replacement Corsair 350D Mid Tower Front Bezel Plate. The ventilation area of holes on this plate measures 5.25" x 7.25", but I can extend it on the 750D & 900D version.

 

 

 

 

 

 

We're going to try the same technique with a 750D front plate this week.

We had to make larger fixture for drilling the ventilation holes in the 750D front plates, but turned out pretty good!, http://mnpctech.com/mnpctech-clear-case-pc-panels/corsair-750d-front-plate/corsair-750d-cnc-milled-vented-front-bezel-plate.html

 

 

Thank you Dustin! Sorry for late reply, I've been swamped with build commitments for CES, Will you be attending CES representing Corsair?

 

btw, I co-designed the 400R Carbide case with George for Corsair in 2010. it just gotten the Golden Egg award from Newegg, be sure to let him know :biggrin: