As I started trying to test-fit the various parts into the DB4, I began to hit various issues that meant I needed to change how the internals were laid out:

• The GPU installed directly into the motherboard PCI slot meant that the hardline tubing was tricky and not very aesthetic.
  
• Cable routing was going to be tricky and unsightly.
  
• Pass-through holes in the base were needed to run tubing to the external radiator.
  
• With the PSU situated, various IO was blocked or inaccessible.
  
• Sub-optimal convection airflow.
  

As you may have seen from my other builds, i've done a little bit of 3D printing and I use Fusion 360 for my design work. So leaning into what I know, I set about designing a custom baseplate for this project.

I meticulously measured, re-measured and measured again all of the dimensions of the original baseplate. I then transferred these into my design, and began making the necessary modifications. I moved the GPU to run parallel with the motherboard (similar to a vertical riser mod), made my pass through holes, moved the power switch and LED to a different corner, moved the power socket cutout and added a ton of ventilation holes specifically for the PSU but elsewhere as well. The only part that stayed original is the cutout for the motherboard IO tray.

I 3D printed a lo-fi version of the baseplate to do some test fitting, and made various revisions (24 to be precise!) until I was confident I had the design perfect for my needs.

Initially I tried to get my custom baseplate made locally by my local machine shop. They weren't geared up for this level of CNC, but they were able to offer me a waterjet cut version (2D only) for a very reasonable price.

Using this I did a full test build, including filling the loop and running/benchmarking the system - even a bit of overclocking! It was at this point that work/life got in the way and I had to shelve the project.

2024 Update
I found myself thinking about this project again recently, and decided to pick it back up. I started searching online for CNC services and found a number of options that provided instant quotes online based on your CAD files. One of these options were a company called GEOMIQ.

Uploading my CAD file to GEOMIQ, they gave me an instant quote that was very reasonable. I noticed that they also offered various finishing options, and so I updated my quote to have my part machined, bead-blasted and anodised black to match the finish of the original part. The quote that came back was only slightly more expensive than the raw machining, so I ordered the part and waited.

I was elated when the part arrived! It looks almost OEM, and all of the work with 3D printing and waterjet cutting has paid off big time. I'm really pleased with the outcome and wish i'd come across GEOMIQ back when I first started the project.