Our answer to Zalman: 0dBA project, rev.1

Channels should go straight on base and cover joint and in my variant they were on the cover. But, firstly I thought that I just vice it wrong. And I spoiled one more heat-exchanging device. Then I lost my heart and went home. The next day I was thinking of "what to do" and “who to blame” and I found the real reason. And that meant that I should use another drilling method, because I hadn’t got alternative material for covers. But when I recalled the construction of coolers on some types of video cards I decided to make square pipes and to mill square gutters in the base of heat-exchanging devices. And I didn’t somehow process this detail. The only function of this detail was press down the pipes. Then I tested new technology on my device and found no problems: I milled it for 15 minutes and I squared the pipes while I was fitting SilentMan. The pipes fit perfectly: I made gutters a bit smaller and I needed only to put the pipes in, to snug down the cover and to drive it in with a hammer to make it completely fit the base. And I forced the pipes so hard that I needed to put it out with a screwdriver.

Then I took two broken heat-exchanging devices, removed 5 mm aluminum layer from the broken sides and repeated the procedure on them. All was good and then I recalled that I forgot to shoot the work process (as always). I took my camera and shot the current work process:

The next day in the morning I started the final fitting of all the details. I unscrewed the big radiator, positioned outmost radiators and screwed them. Then I inserted the mother board and bent remaining four tubes. Here's what I've done: