WMD Part I by G-gnome

End Covers - 3

To conceal the intake required a means of maintaining a nice air gap while still covering the intake hole.



I started by tapping the inner ring of holes to M6. The number and position of the holes is identical to the end cover on the opposite end of the case, all designed to make each end look as similar as possible.



Once the holes were threaded, I laid a piece of steel across the piece and measured the distance from the top of the flange to the bottom of the steel. I planned on making some spacers that would make the end cap sit as it would if the whole piece was flat, like the one on the DVD end.



I marked this distance on the piece of tape that was still there from making the threaded tubes for the fasteners. However, this time I used a larger bore stainless tubing - 6.5mm ID - the perfect size to run an M6 screw through. I started by cutting a short piece off the end to square it up....



...then cut 10 short sections of tube. These had the sharp edges filed off.



The remaining end plate was drilled to 6mm...



...and longer M6 screws were pushed through. A section of tube was dropped onto each one.



You can see that they are just longer versions of the screws used on the DVD end, all helping to keep a consistent look to the case. The screws were tightened progressively around the disc. If I had've completely tightened one first, it would have tilted the disc and made it difficult to tighten the other screws.