custom Quark case design
 

Here is a quick 'sketch' of a Quark case idea of mine. I don't have the proper measurements, so it might be off (and is). So now the top FET's would get cooling now, that part about the Quark really bugged me, a heat spreader would almost do nothing for cooling them. The power stage board will be pressed in between the blue plate and the case.

Not all the features I made on it yet, like the slots for the top cover, and slots for two end covers.


Click HERE They are the bottom 6 pics.

Also, I did catch a video of my BL maxx before the Quark died, it was pretty sick for power.

HERE

Yeah it's sick for power...you should build a ramp and jump that building in the backround!

Yeah, jump the building and drive up the side of the it too... evil knievel!

The Quark case is same length, and hight as stock case, but is 12mm wider.

what about adding a little mass to the underside. so you can crew it on the motor mount like you do with the mount mike has in his store.

Yeah, that's a great idea! How thick should the bottom be then for this?

Or should it be like screw on heatsink that mounts to the motor mount, so a person would have more options for mounting it? :027: Personally, I don't think it should thermal the way it is, as it would take alot more heat away from the FET's. But, for me, I like to go the extra mile.

The case looks solid. I like it. I'd pay for it. Just make sure the stock pastic covers and all work on it. I want one thats anodized in black!

I really like the idea of having a spot on the end that will screw to the empty motor mount position like the RCM heatsink. I also agree that it could use more mass on the bottom.
Make sure you mill a few slots in the extra mass on the bottom to allow it to help it disipate heat to the air and a couple screw holes for mounting a fan too it also. I would make that plate that goes in between the boards out of copper to get the absolute best heat transmision possible. Also make sure you get a really good thermal compound on the ends of that plate where it attaches to the main case body.

How are you planning to attach the fets to the case and the middle plate? What keeps them in solid contact?

Thanks for comments! :)

Black anodizing would look killer! The stock greyish anodizing would be nice also.

K, I think I will add 5-7mm on the bottom, but i also have to extend each end I just remembered, for motor and power wires. I will make the bottom a heatsink with the same fan mounts as the RC-monster one (not that it should need it, but still).

Yes, you would still use the top, and side covers with this, although it doesn't show the slots where they go yet. I was thinking whether to use alum. or copper for the center heatspreader, but I think you're right, copper may as well be used, as that is the most important part.

I am still wondering if mount the board in there will be okay, I know if you de-solder the motor wires it should be fine, but if you leave them on, I don't know, maybe it can be done.


If anyone is interested at this point, let me know, and let me here some feedback about it if you want one. :dft009::)

:004: sick emaxx man!!

FYI: When you epoxy the internals in there, you may want to think about putting some epoxy on the caps. It won't be perfect, but should help pull some heat away from those caps...

oh oh oh, no no, there will be no epoxy to be had in this case, just thermal paste, arctic silver. It does clamp the board, so you don't need/want epoxy, and you can always take it apart too.

I have to get the distance right between the two plates, as to get a good pressure (but not too much) on the FET's for good coupling.

I am just modifying it right now, with heatsink bottom, and motor mount holes. It should be good.

Thanks Mach1stang! :027:

Alright, I now need to know the hole pattern of the RC-Monster heatsink.

What is the middle screw hole for on the heatsink? (motor mount ends)

What is the spacing of the fan mounting holes?

I'm kinda stumped on what fin design I should make on the bottom of this. I need to make it so they are durable, so you can strap the heatsink down onto something (FLM chassis for instance), or on the motor mount and use air flow effectively. I'm kinda leaning for serrated fins

Also, I really don't think fans will be needed at all on the thing, with a good fin structure on the bottom. It should keep the FET's very cool and happy, would be able to run all day long.

Does anyone with CNC experience know what the smallest feature (flute/bit) can be machined? Is it 2mm? And what about the end of the bit/flute, are the small ones round or flat, or both?

Thanks for the help.

Here is what I am thinking with an integrated heatsink, it looks pretty good too. Too bad I spent all day designing it when I have to completely redesign it when I get my Quark back (for measurements).

zero, I hope you don't mind, I got bored and played w/ your design some. thoughts?

http://a4dtm.com/quark/zp/4.jpg
http://a4dtm.com/quark/zp/3.jpg
http://a4dtm.com/quark/zp/1.jpg
http://a4dtm.com/quark/zp/2.jpg

:018: :018: :018:

man you guys can do some nice stuff on CAD.

:018: :018: :018:

WOW, nice job A4! holy crap, that sure is nice! Is it accurate for measurements?

I REALLY like the top cover, I was actually playing with the idea of having something like that. I like how you made the clamping a little narrower and made fins on the outside from the FET's.

The way you made it, it would be much easier to mount the board in there compared to my design.

So.... is your design all do-able? Like as for the parts you have there, like the button, the acrylic cover?

Keep it coming, make something like my second design with the heatsink on the bottom... :027:

ZPB

Also, do you know what kind of fin pitch (heatsink) is capable with the typical CNC machine?

Thanks! It's all in the mind though, the CAD just allows you to shine through. :dft009:

:o :o

aah, what's the matter A4? to tired? :005:

That's cool. Yeah acrylic would look frosted if it were machined (i think). But if it weren't, you wouldn't need the led cover, just the see through top cover would do...

I would like to make a case that would be sealed from dirt and debris, that to me is another killer of controllers, minerals all over it, insulating it thermally...

NOTE: AAngel, that alum. oxide paste you made, is it permanent? Can it be taken off?

A4DTM: Would you mind emailing the CAD file to me, I would like to look at it a bit and modifiy it.

I am using Alibre Design Pro. PM me

I have been playing with several designs for this case, I am wondering if I should integrate some screw hole mounts with 50mm centers (stock EVX) onto the sides of the case?

Seems like I am doing a monologue. :032: :p

New design, doesn't have motor mount holes yet.

I'm sold. Put it into production and I'll buy it.

SSSPCONCEPTS:

Would you rather have the flat bottom, so you can use RC-Monster heatsink/mount.

Would you rather have integral heatsink on bottom w/ mount screw holes on each end of case?


Also: Does anyone know the dimensions of the RC-Monster heatsink, the length?

Thanks

integral is better IMO

where can we sign up for beta testing?:005:

I agree!

Would you guys seriously want one? PM me if you are serious about getting one. Mike hasn't replied back yet about it; can he machine this even?

Here it is with motor plate mounts on it.

hehehe, this thing will prob give the Quark a 200 amp capability with a few extra capacitors on the system. :027:

Here is a pic of what it more would like assembled (with stock plastic covers of course).

cool but what about an version without the slots for cooling but solid aluminum

this will make the case significant cheaper
or only slots on the under side is also enough for me

Mine is 84mm long.....the heatsink, you dirty minded people.

That design is looking pretty good, if it has a flat bottom then it would be good for mounting to the chassis of a 1/8th, but then if it had fins on the bottom and mounting holes on the end there would be one less thing for an e-maxx driver to buy. Personally I have the RC-Monster heatsink already, and I have a 1/8th that I will want to put the Quark in soon, so I like the flat bottomed version with screw holes underneath.

Geez, I was hearing that ppl would rather have integral heatsink on bottom? You will still be able to mount the bottom on anything, it is flat heatsink, no problem there.

I will see how much a heatsink bottom will cost, and one with flat bottom.

thanks Patrick

hey i have got to say that it looks great.
would be interseted in getting one if the price was right.

I like an integral design.

Yeah, me too. I think it's best keeping to one design, and integral is my middle name.

This is what an R/C MT esc should be with this heatsink, the Quark... even if S&T made the top set of FET's coupled to the chassis, that would be worlds better.

CAD program says the outside surface area is roughly 300cm2. That should do the trick. :017:

So maxxman, nieles, ssspconcepts, patrick, A4DTM, jhautz are you guys seriously interested in getting one for yourselves?

Again, the design is not to specs, I don't have my Quark back yet from S&T, so it's going to have to wait for it to get here.

Does anyone happen to know a free thermal simulator program that I could use on this case?

ZPB

sorry,
no idea's about the thermal simulator program, but if the price isn't sky high i may get one, as they look sick!

there was going to be some room for some extra capaciters wasn't there.
You say that the outside surface area is around 300cm2 but i was wondering what the surface area was on the original one.

Thanks.

The more ppl we can get, the cheaper it will be per unit. Mike still hasn't replied back yet though.

The stock Quark case is roughly ~60cm2, but also the thermal coupling between FET's and case is very poor. So this one has 5 times the surface area plus superb heat transfer from top and bottom FET's. I can bet under normal MT conditions the FET's will only get 10 degrees (maybe less) warmer than ambient temp, but just a guess.

Oh, there is no way I can make room for extra caps on this, it would simply be too large. Caps are going to have to be added to power leads externally.

try e-mailing him again

i e-mailed him some time last week maybe thursday and got no reply.
So i sent it to him yesterday and he came back today. he also told me that he was having,
"a few struggles with the site lately(wacky computer/web stuff that I am largely unfamiliar with) – I apologize for delays in response relating to this."

i am still wondering if therewill be any room for extra caps.