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[Project] Gizmo - Super Thin AIO AMD system - DESTROYED :( - Page 2

post #11 of 86
Thread Starter 
Quote:
Originally Posted by fwaggle;14127378 
Do the cones on the bottom "speaker" move? If they do, it's probably a passive radiator.. not a complete sham in that case.

A good point, as it does move if pushed but it's not a passive radiator as it is not a cone design and it has a heavy flat disc of steel on both the front and back.

So even if it was meant to be a passive radiator it wouldn't do much if anything with the little amount of air displacement from the one drive coupled with the additional mass added to the phoney speaker.
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post #12 of 86
Thread Starter 
I am back after a two week vacation, and it's time for updates.

I have begun the preliminary acrylic work, below is generally where i plan the components to end up.

5889265614_2e77fc8c91_b.jpg

And after a little measuring and holesaw action in the drill press the speakers have somewhere to be mounted. This panel is 9mm (3/8") thick black acrylic.

5889265884_f6998fe8ea_b.jpg

Next up comes a big task, heat forming the base of the unit. This is also made of 9mm thick acrylic so it will take a lot more heat than what I am used to in order to make it bend.

I made a basic jig to ensure that the bend would be square and where i want it to be.

5889266514_bd82c5587e_b.jpg

7-8 minutes of heating up the panel later it just barely starts to bend ever so slightly.

5889266816_5f25878690_b.jpg

After 12-14 minutes it finally gets soft enough to get to some serious forming.

5889266996_88c197acc2_b.jpg

This is why I needed it so workable, a 110° angle bend.

5889267124_6b7c48c884_b.jpg

And here it is without all the rigging.

5888698659_a022979cbd_b.jpg

I then got to work making all of the necessary holes and cuts to the base panel for the relocated status LEDs, audio controls and the new power switch. Oh yeah, I cut the audio control IO panel out of the old speaker body and will be relocating it to the front panel.

5889269106_8e06f23ef4_b.jpg

Things are starting to fit after a bit of cutting and light machining.

5889269382_dbf40513dd_b.jpg

Here's the back side.

5889269504_c68de81ae0_b.jpg

And all done here.

5889269642_5a325e55d6_b.jpg

Next step: Building a custom PSU for this thing.
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post #13 of 86
Thread Starter 
So now its time for some important and potentially dangerous work: Making a PSU for Gizmo. The staring point is the stock AC adapter for the notebook, it is a basic LiteOn model with a three prong power cord.

5888695939_db497e3916_b.jpg

Stripped of the plastic shell you can see that the PSU itself is enclosed in an aluminum heat spreader.

5889264848_11dd58d9bb_b.jpg

Inside we see the usual notebook PSU stuff, on top of the MOSFET and driver transformer areas is a white factory applied TIM.

5888699543_0b4a63a40c_b.jpg

There are two more AC adaptors to be integrated into the unit.
  1. The sound system has a simple single chunky transformer PSU
  2. And there will be active cooling of the PSU, so PSU for a 120mm fan will also need to fit in there


Now I need a home for my various adapters listed above, what better home for a PSU than an actual PSU? I just happen to have a dud of a PSU kicking around that I could use the casing from.

5889267564_694a08e158_b.jpg

Most of this is headed to the electronics recycling facility, and i found a blown cap in there explaining the voltage issues this PSU had at the end of its life.

5888699257_5c327ddc12_b.jpg

The power socket and power switch will be kept as a master power switch for the entire system, and allow me to use a standard AC power cord with the machine smile.gif

5888699419_e41e83ed31_b.jpg

And here is my shell ready to go

5889268396_d3e1999807_b.jpg

Now that I have a case for my PSU parts, lets move onto actually getting everything in there and working. Oh, and I painted the PSU white as galvanized steel is too "meh" looking for this build. smile.gif

First off I decided to go with a modular internal design using molex connections, this way I can easily replace components individually if needed in the future.

Lets meet the rest of the parts, yes it looks a bit daunting at first.

5888699919_b117123cb7_b.jpg

Here is the 120mm fan power supply

5889268986_8a2296c9ec_b.jpg

The Audio system PSU and its freshly harvested molex pins ready for soldering

5889268862_6f5fc916b8_b.jpg

I built the AC power distribution cables next. The molex parts came from the original PSU I used for the case, and that is a stripped laptop power cord. I had to strip off all of the casing to get it to fit into the PSU shell when it is plugged into the notebook PSU.

5948233724_eebf435802_b.jpg

I built a new floor for the PSU out of white acrylic allowing everything to be mounted onto a non conductive surface.

5947678043_9bb7fe0e70_b.jpg

And here I started assembly of all of the components

5948234134_4f881031dd_b.jpg

The notebook PSU used to get really hot during extended use, so to increase the transfer of heat I added a few dabs of MX-2 to the thermal contact points when i re-assembled the notebook adapter.

5947679399_b9f737f5ed_b.jpg

I looked into my parts bin for a low profile heatsink that i could apply to the notebook psu to improve cooling performance. I found a perfect parts donor.

Ooooh Purple Anodized!

5947678611_4bed87e77a_b.jpg

This is a real odd-ball from the late 90's. It is a 350Mhz PowerPC 750 CPU upgrade card on a NuBus interface out of a PowerMac 6200 I think. Note the external 512k of cache.

5947678941_25bd13eece_b.jpg

And about to bond it using Arctic silver thermal adhesive, I like that stuff a lot as I am sure you can tell if you have read this far.

5947679589_ede81a8e7b_b.jpg

Next came the big test: plug it in and see if it works.

5948235610_ca17e9ab76_b.jpg

Verdict: Success!

Below you can see the fully function and almost finished PSU running.

5947680111_51c2abf992_b.jpg

What is left for the PSU is cable sleeving and attachment to the notebook motherboard and audio control board.

Thanks for looking smile.gif
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post #14 of 86
Thread Starter 
Progress made for the second day in a row! Nothing too photo worthy though as today's work was a ridiculous amount of sanding, wet sanding and buffing of the two main black acrylic panels. I will post before and after shots of that tomorrow and I started the motherboard mounting assembly pics of that also to follow. Thanks for looking smile.gif
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post #15 of 86
sub'd. You have some of the best work on the web
post #16 of 86
Thats some good Frankenstein style modding for the PSU but not as much as that other one i saw where they hooked a few dozen laptop batteries together lachen.gifhttp://www.overclock.net/case-mod-work-logs/881695-project-ghettobook-23-inch-laptop-updated.html
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post #17 of 86
Wow, this is something you don't come across everyday.

Awesome work and subbed! biggrin.gif
post #18 of 86
Nice job so far, looks to be a really clean build.

However I cannot condone what you have done with your power supply, it could have been okay if you had hard wired the components in, but using standard molex connectors is just a big no no. I have worked with mains voltage before, needless to say its dangerous, but if you are not using a standard connector or hard wiring it you should use different plugs so that it is not possible to mix different connections up. Just my two cents.

I love the build though, looking forward to seeing it done smile.gif
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post #19 of 86
Thread Starter 
Quote:
Originally Posted by KG363;14264175 
sub'd. You have some of the best work on the web

Wow, thanks man! smile.gif
Quote:
Originally Posted by Thedark1337;14264446 
Thats some good Frankenstein style modding for the PSU but not as much as that other one i saw where they hooked a few dozen laptop batteries together lachen.gifhttp://www.overclock.net/case-mod-work-logs/881695-project-ghettobook-23-inch-laptop-updated.html

That is a truly epic project, I can't wait to see it finished and thanks man smile.gif
Quote:
Originally Posted by jjjc_93;14267598 
Wow, this is something you don't come across everyday.

Awesome work and subbed! biggrin.gif

Cool, thanks smile.gif
Quote:
Originally Posted by mcpetrolhead;14267662 
Nice job so far, looks to be a really clean build.

However I cannot condone what you have done with your power supply, it could have been okay if you had hard wired the components in, but using standard molex connectors is just a big no no. I have worked with mains voltage before, needless to say its dangerous, but if you are not using a standard connector or hard wiring it you should use different plugs so that it is not possible to mix different connections up. Just my two cents.

I love the build though, looking forward to seeing it done smile.gif

Thanks man and I can address the use of the molex connectors as being safe for their intended use only.

I was looking for a simple solution to make the internal components of the PSU modular so that I could easily replace individual parts if needed, hard wiring would complicate that. I was leaning towards using Pigtail Connectors and talked to a neighbor of mine who just happens to be an industrial electrician, he suggested using the molex connectors as they would allow easy changes, can only be plugged in one way, and wont light on fire as the current draw is very low.

You are very right in mentioning that dealing with line voltage is dangerous, and it not something to mess around with. If someone was to plug a hard drive or something meant for 12v DC into one of these molex connectors it would likely light on fire and electrocute the person holding onto it. I thought of that as a concern and made the connections too short to reach outside of the PSU enclosure. I will also mention that prior to plugging in the "Franken PSU" my neighbor the electrician checked it out, I don't want to get shocked or potentially worse skull.gif

More updates to come later today smile.gif
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post #20 of 86
Subbed, looks awesome.
    
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