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PowerHack G5

post #1 of 23
Thread Starter 
Here is my build progress of my second ever case mod, and while it is not as fancy as some of those seen on here, my plan is to make it look as close to a stock Power Mac G5 as possible. This worklog is also paralleled at tonymacx86.com, but I want to show it off here as well!



Today I have ordered the mountain mods motherboard tray that seems to be very popular around here, as well as a bunch of M3 screws from McMaster Carr and some 2x5 pin headers to do the custom wiring for usb, audio, power switch, etc. I'll post pictures of my progress as soon as I upload them and crop them

Table of Contents:

1. The Parts List (6/21/11)
2. Layout and PSU Mounting (6/25/11)
3. Fitting the Motherboard Tray (7/6/11)
4. Feeling Blue, Carving a PowerMac (7/8/11)
5. Blu-Ray Burner, Front Panel, A Little Bit of Paint (7/14/11)
6. Water Cooling! Graphics! and Paint! (8/4/11)
7. Finally! What You All Have Been Waiting For!(8/4/11)
Edited by eovnu87435ds - 12/7/11 at 5:07pm
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M8
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post #2 of 23
Thread Starter 
I took the plunge and bought a Water-cooling system from http://www.swiftech.com/ ! I got the Apogee XT CPU waterblock, KOMODO full GPU waterblock for my ATI radeon 5870, MCR220 2x120mm radiator, MCRES Resiovoir, and a MCP655-B pump. Along with it I got some 1/2" ID tubing, and PC ICE in UV Electric Blue. So far, I am still waiting on everything except the screws and nuts, my new power supply, and the pc ice.

And now, PICS!

IMG_2796.jpg
Washing all the crud that was left inside from the previous owner. Dummy me then tried to take it out just after it finished its heated dry cycle, and melted some skin onto the case door. Aluminum sure does conduct heat...

IMG_2792.jpg
The giant pile of hardware needed just to get the case apart

IMG_2951.jpg
Half inch m3 standoffs, weldable m3 nuts, blue anodized M3x10 buttonhead screws, and m3 nylock nuts. I <3 McMaster Carr

IMG_2944.jpg
PC ICE Coolant. It's actually blue, not black.

IMG_2946.jpg
Rosewill 1000w (semi)modular PSU
M8
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M8
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post #3 of 23
Thread Starter 
So the first pic below is what I will be trying as my basic layout that I am going to build off of. In addition to what you see here, my 5x 2.5" hard drives will be where they were originally located. I still have to work out radiator space.

IMG_2886.jpg

What luck I have! I chose M3 hardware because I do have a decent amount of M3 stuff lying around from hobby grade remote controlled cars, and what do you know! not only do the M3 screws fit perfectly through the perforated mesh, but the screws that hold the PSU case together are m3, and those screws match up perfectly with the mesh pattern! So I was able to put 4 screws through the front, with a nut on the back to act as a spacer, and presto: my PSU is mounted!

IMG_2948-1.jpg
Screw and nut

IMG_2952.jpg
You can barely see the PSU through the mesh.

IMG_2952.jpg
There it is from a side view.

I have this awesome power cable that comes out on a 90 instead of straight out, so that can plug in to the PSU, and when I get everything close to finalization, I will cut the power cord off and solder it to a socket that is sitting in the stock socket location

IMG_2955.jpg
The sideways cable lets me keep the PSU as low as possible

IMG_2956.jpg
Here is the socket I will cut and solder that cable to


Now I am just waiting for my mobo tray and Water kit to come in before I start doing any more fabrication
M8
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M8
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post #4 of 23
Thread Starter 
So my Mountain Mods Tray came in, and I realized I made one little mistake when ordering...

3013.jpg

And this thing took so long to to get here, I swear, FedEx must've hired someone to walk it across the country to my house. There is no way I am returning this... and in comes in what I call "The Adjusters."

3014.jpg

So I drew everything out using calipers, squares, and rulers to make everything look nice...

3015.jpg

...and used a tablesaw and jigsaw to cut it out

3016.jpg

Here's how it will look!

3017.jpg

Since I didn't have any more dremel cutting wheels, I cut out the expansion card slot with an angle grinder. Surprisingly I didn't cut up my chassis.

3018.jpg

3019.jpg

3020.jpg

I then added half a dozen standoffs to the motherboard tray, so that when I attach it to the chassis, I have some clearance to run my wiring underneath the motherboard.
3021.jpg

3022.jpg

The next 3 pics are with my mobo in the tray, ready for fitting. The second graphics card is just a placeholder that I put in to help hold the tray sturdy. Funny anecdote about the radeon 5870- In my previous case, there were no slots for the "tongues" of the pci card, so I had bent them at a 90 degree angle so the card would fit in and attach to the motherboard. I had to flatten that back out in order to work in a proper case. I guess this is the only time anybody has fixed their $400 graphics card by smashing it with a hammer :thumbup:

3023.jpg

3024.jpg

3025.jpg

And here is the final placement! It is held against the back with just 1 screw and is sitting against the chassis at the moment

3027.jpg

And here it is from a bird's eye perspective. I thought it was fitting because when taking this picture a bird flew into the garage and scared the crap out of me, hit the wall, fell and hit the floor, then got up and flew away.

3028.jpg

And last but not least, here it is with the outer plate on.

3030.jpg


As you can see, I still need to cut out the I/O / PCI hole, and I need to patch up the stock fan holes. For now I am leaving those stock fan holes, but I want to buy just the front grille of another power mac, so I can cut a piece out , JB weld it in, and make it look like there was never any hole there. Obviously, if anybody has any spare G5 grilles, please PM me!

Until then, I plan on using a bit of crazy glue to hold the standoffs in place where I want them, then removing the motherboard tray so that I can JB weld them real good without anything in the way.
M8
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M8
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post #5 of 23
Thread Starter 
While waiting for my JB weld to dry, I decided to paint the motherboard tray and I/O shield metallic blue, since everything inside the case will be a nice electric blue color!

3031.jpg

2 Days after the JB weld was put on, I decided to continue working on the I/O panel, so I used the jigsaw and cut out the inside so my ports would be usable! To do so I had to nearly bolt the entire case back together in order to hold everything down in place. Even with everything held down as much as possible, the saw would start to grab and shake everything to bits. it shook so much that the latch, which looks to be spot welded to the chassis, shook right off! In the end, it is looking pretty nice, although I need to go back and take a little more off the one corner. After that, I drilled out where my screws go, so that I could bolt the tray pieces together through the mesh, and make everything alot nicer and alot sturdier. now all that's left is to take care of that hole!

3036.jpg

And Here it is with everything so far bolted in place!

3037.jpg

I've recently contacted Swiftech about my water cooling stuff, but unfortunately they still have no word on when they will be getting the GPU block I ordered... I kinda need that, along with the rest of my order, pretty soon, as I need to make room for a 240mm x 120mm radiator in this case!
M8
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M8
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post #6 of 23
Thread Starter 
So I got a new piece of hardware for my Power Hack, and since I had some time to work on it, I get to bring you another update! I picked up a used Sony BWU-200S Blu-Ray Burner!

Sony-BWU-200S-Blu-ray-burner.jpg

So what was the first thing I did with my new expensive drive? That's Right! I voided the warranty! I ripped it open and soldered a pair of leads that now are just dangling outside the drive. soon I'll cut and trim it and do some sort of hidden dvd drive button.

IMG_3038.jpg

IMG_3039.jpg

After wiring that up, I worked on the plate that holds the drive in place. I had to do some cutting so that I can still keep the latching system, but had room for the motherboard. I ended up with this:

IMG_3042.jpg

I then put a coat of flat white paint, followed by premium wheel paint, which looks pretty close to the mac's brushed metal look. I may end up doing the entire case in this stuff!

In between coats of paint, I worked on soldering up my front panel adaptor, using some 24 gauge speaker wire and some 5x2 female headers to plug into my motherboard.

Here's my parts and reference sheet

IMG_3043.jpg

And the soldered main header(i glued 2 headers together.) This gives me a power button and power LED. in addition, my pc speaker is a 4 pin plug that can just plug into the header, so I didn't bother soldering it, and it isnt pictured.

IMG_3045.jpg

And the mac side of the cable, all done up. I just put some heatshrink around the unused FW wires, just in case I ever get a different mobo with firewire support.

IMG_3046.jpg

After that was done, I used some wire tie pads and some wire sheathing to make everything look nice and neat when done. That, and it lets me hide that extra 3 inches of slack under the motherboard.

IMG_3048.jpg

Here is what the motherboard looks like with the main, usb, and audio cables plugged in.

IMG_3049.jpg

IMG_3050.jpg

After the wiring was done, I decided to bolt in the blu ray drive too. Boy was I really lucky! The blu ray drive was a bit longer than the cd drive I tested with, and it literally just fits!

IMG_3051.jpg

IMG_3052.jpg

And so that was all the work I could do last night before I fell asleep, so here is the overview so far!

IMG_3053.jpg

And here it is with the ugly metal front piece that the latching mechanism attaches to. I painted that too. I just need to disassemble the whole thing to actually put it in!

IMG_3055.jpg
M8
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M8
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post #7 of 23
This looks like its going to shape up to be an awesome build! I honestly had never even thought about putting a case in the dishwasher to clean it before. I cant wait to see this thing finished!

subbed
HELLFIRE
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post #8 of 23
Looks good.

I modded a G5 a while back, and it was a ton of fun.

I was amazed how strong the aluminum was in the back, I burned through a ton of Dremel wheels cutting it up.

How will you mount the tray to the case?
Edited by trueg50 - 7/28/11 at 8:20am
    
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post #9 of 23
Lookin good. subbed.
    
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post #10 of 23
I have a G5 case sitting in my garage.. I was going to do the same exact mod as you but never got around to doing it tongue.gif
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