Making the Waterblock

I originally planned to use a standard PC CPU or chipset water block but after trying about 10 different blocks I couldn't find any that I was happy with. The CPU was no problem but theres around 15mm clearance between the GPU and DVD drive which causes the problem.

Instead I decided to make a new block to cover both the CPU and GPU.

I didn't want to spend much on the new block so I made the most simple block I could think of. The block is made from a single piece of aluminum with a simple channel cut into it with a bench drill.

Aluminum bar from http://www.metalsontheweb.co.uk

On the top of the bar I cut holes for 2x 10/8mm compression fittings. I used a 1/4” BSP tap to cut the thread. Three other holes were cut through the block for the water path. This left 5 holes which would need blocking. In each of the holes I cut a 1/8” BSP thread.

On the base of the block I drilled 8 holes and tapped a thread for the pegs. The pegs were removed earlier from the original heatsinks they have been used so the original mounting clips can be used.

Each of the 5 holes from the water channel were blocked with a 1/8” BSP brass plug. The plugs were screwed in past past flush and an epoxy resin, a thread sealant was also used. After sealing the block it rough so I covered up my handy work with paint.

After painting the base of the block was lapped. Sorry about the quality of some of the photos.

The finished block with mounting pegs installed.

Luckily the pegs lines up perfectly with the 8 mounting holes.

The backplates were fixed back on to hold the block in place and apply pressure to the cores. Arctic silver ceramique thermal paste was used on both cores.

The block was then removed from the Xbox and leak tested for 24h.