[Complete] Jessie's Gumdrop

Jessie's Gumdrop
Runner-up - 2nd Place - June 2008 OCN Mod Of The Month

One shot of the completed project... (better ones in day 11,12,14 updates)


Jessie's Gumdrop - Day 01 (this post)
Jessie's Gumdrop - Day 02
Jessie's Gumdrop - Day 03
Jessie's Gumdrop - Day 04
Jessie's Gumdrop - Day 05
Jessie's Gumdrop - Pro Paint Consultation
Jessie's Gumdrop - Day 06
Jessie's Gumdrop - Day 06 Update
Jessie's Gumdrop - Finish Parts Overview
Jessie's Gumdrop - Day 07 - Back From Paint!
Jessie's Gumdrop - Day 08
Jessie's Gumdrop - Day 09
Jessie's Gumdrop - Day 10 - Final Assembly Begins
Jessie's Gumdrop - Day 11 - Final Assembly! Final Assembly Continues...
Jessie's Gumdrop - Day 12 - Final Final Assembly Part I
Jessie's Gumdrop - Day 12 - Final Final Assembly Part II
Jessie's Gumdrop - Broken Scroll Saw!
Jessie's Gumdrop - Day 13 - Acrylic & Scroll Saw Adventure
Jessie's Gumdrop - Day 14 - Project Complete!

Jessie's Gumdrop - Ghetto Child Safety mod

Jessie's Gumdrop - 1 Year Fix & Maintenance


The first thing my wife thought when I told her the name for this project was that I was somehow making a gum-drop shaped case. While that may be a cool idea, its not what I am doing. The Gumdrop name simply comes from the color I chose for the case (Krylon Gumdrop), which is like a light purple color

Krylon Gumdrop


Anyway, this project is a pc case for my 2+ y/o daughter, Jessie. I am basically resurrecting and modifying an old beige case from my old PII-400 circa nineteen-ninety-something. It will house the current pc she is using which is a pIII-800 with a fx5200, and 384mb ram - lol. This project is about the case, not the internal pc specs

Day 01 begins, here's the donor case...











First thing I wanted for it, which I thought would look cool, but not so functionally necessary, was a nice 120mm blowhole. Originally I was going to do it in two separate cuts, one for the chasis, and one for the bezel. Then I remembered watching Bill Owen's Turbine fan mod and seeing him make the cut look easy in one shot - so I went for it...

not bad! the Dewalt power drill and the 4.5" holesaw made quick work of the case front. I wont lie, it was a bit scary at first. I just made sure to keep the rpm's up and the pressure low so as not to bind the saw. I think the cut came out pretty clean.



After a bit of filing with a half-round double-cut file

The case door panels are being swapped because of this vent you see in the stock left panel. It was going to interfere with the window I am doing in that panel, so I swapped them. I decided this stock vent, which is now in the upper portion of the right panel, needs some improvement. Holesaws anyaone? 1.5"...

prepped and ready to go

muha!

during that cut a piece of sharp steel hit me in the cuticle on my thumb (since I was using my left hand to hold the panel that was hanging over the table edge, to try and steady it. I guess it was too close in proximity to the cut) It didnt hurt, and I didnt even notice it until I saw blood. Its like a tiny spec but it bled like a sieve . thats my makeshif bandaid and paper towel contraption. Note to self: get some bandaids for the workshop.

Now to connect up the hole cuts with the dremel jig saw

prepped

Done. after I started this cut I switched to using a reinforced disk instead. The jig was fine and cutting nicely but since currently I dont have a way to support the material on both sides, the thing was flopping around like a fish and it was loud and inefficient. Using the disk took a little longer but it was easier to control. I think the cut came out clean.

from the finish side, after some filing with the half-round and flat bastard files

When I tried to remove the collar and pilot bit from the 1.5" holesaw, I realized it was bound up so I busted out some helper tools...

All freed up. Is this why they put holes in the sides of holesaws? So you can stick a screwdriver thru it for leverage?

Reassembled the case to assess the damage...







Not too bad for day one I guess Day two will include a couple more cuts and some sanding prep. I cant cut the window yet since the acrylic hasnt arrived yet from mnpctech. Thanks for reading. I will post more updates soon

CR



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Edited by CattleRustler - 11/21/09 at 6:01am

Thanks, me too

Yep thats me. I have been a member there since 2003 iirc, and a moderator since 2004. Are you the same nickname here as there?

thanks, yeah I hope so, she picked the colors
As far as the acrylic cutting I just need to cut the panel down to size with one or two straight cuts, I am not cutting holes in it or anything, so I assume I can use a jig or disk to cut it. Not sure about it when doing screw holes or fan holes, you could probably use drill bits for plastic which have a different angle and rake compared to for-wood/metal bits.

Thanks
Lol, yeah - shed have a better cpu than me then

if you mean to cut the case steel, I use the 1.5 reinforced cutting disks from dremel. I got a 5 pack from mnpctech, but you can get them pretty much anywhere, also they have them in the ezlock mode as well. If you mean for acrylic I havent cut any acrylic yet. Repo man posted some info above.

Lol @ Repo - thanks for the info and the potential offer. We'll see how this pans out. I think she's fine with the p3-800 for now tho