[Amateur] "Silence" - MiniITX (Scratch) [Tons of Pics 56k Death]

So I decided I wanted to build a tiny, silent HTPC that would be able to play blu-ray movies and some HD content.

This is the log of how it came to fruition.

Index:
1: The Beginning, parts etc.
2: Aluminium shaping and painting test pieces of acrylic.
3: Test piece results and metal frame mock-up.
4: Mobo stand-off attachment and Acrylic Pieces received.
5: Acrylic painting and results.
6: Attaching the acrylic and metal PT.1 + mock-up
7: Attaching the acrylic and metal PT.2 and installing the hardware.
8: Finished Product.


I'd like to thank my family, friends and co-workers for their support in the completion of this mod. I'd also like to thank CattleRustler for making a Worklog Creator tool, which saved me hours of pain and probably was the only reason I was able to finish this on time. Last but not least I want to thank OCN for hosting this awesome contest, I look forward to seeing all the amazing mods that have been created.

Note: My image server has unlimited bandwidth... however they never specified how fast it would be, so there may be intermittent failures to connect or long loading times. I've tried to keep the file size down but there are about 70MB of images here. If it doesn't load properly just refresh until it works.
EDIT: Moved the pics to a new server. Please let me know if you are having trouble viewing them.

Edited by Sparhawk - 10/17/10 at 10:04pm

The very first sketch I ever made. Design evolved a fair bit along the way.

At one point I was considering using wood as the main case material and using the acrylic as a window.

Brainstorming & List of possible parts for the internals.

More sketches and possible construction ideas.

An airflow diagram.

More airflow sketches.

Measurements using numbers I pulled from various online sources.

Numbers for use in Google Sketchup.

More pretty drawings (The top right one is very close to what I went with).

More accurate drawings.

More detailed airflow diagrams.

What I used before I started my eMachineShop/AutoCad document.

More sketches and layout stuff.

The parts arrived! (ordered from NCIX)

Oooh, shiny...

Bluray drive. I had to go with a full-size one because a slim was pretty much impossible to find anywhere.

This was the cheapest 4GB of ram I could buy.

These seemed to have good specs(silent) and were the perfect size.

SSD goodness. Hopefully this will make boot times better and the OS a little more snappy.

The heart/brain/everything of this build.

Looks very slick.

Many ports and connections including: wifi, HDMI, optical out, bluetooth, RCA audio out and on the left at the bottom is the power adapter port. No internal PSU! This was great for keeping size down.

Some more bits and pieces for making cables and connectors etc. (ordered from Newark.com)

Timer module I used to do time-lapse photography.

Very nice little unit.



Remote cable plug that I will hack for use with my timer module. (don't use this cable very much anymore anyway because I have a wireless shutter trigger)



First slices. Had to be very careful to only cut through the outer sleeve.

I see its insides!

tada!
[img]http://lh4.ggpht.com/_XikJAT4dXeg/TDHkeuvQ53I/AAAAAAAAAI0/v7_mJEo-TOY/018.jpg/img]
Sliced. I had to test each pair of wires until I found the ones that when bridged would cause the camera to snap a pic.

Cables for the power/reset buttons and their lights.

Heatshrink tubing to avoid shorts.





All soldered up. Fun Fact: This is the only part of the build that is ROHS in-compliant (silly lead solder).

Glam shot.


* This Worklog post was generated using WorklogCreator - Version: 1.0.1.7
* Free Download: http://www.mod2software.com/worklogc...logcreator.zip
Edited by Sparhawk - 7/5/10 at 7:16am

I decided on perforated aluminium for the inner casing that all the electronics will be attached to.
I bought a 4x5 (feet) sheet of aluminium because that was the smallest I could get with the hold ratio/gauge I wanted.
My uncle cut these pieces for me(because he's awesome and has the equipment in his shop for cutting large sheets of metal).

I had made my measurements and taped up the sheet accordingly. Yes there is a ton of aluminium left over, so possibility of future aluminium mods is definitely there.

This little gal wouldn't leave me alone if I was working outside(she never does and I wouldn't want her to).

Always curious, and never sits still I can only barely get pics of her.

Workbench/table with a small aluminium break I bought for this project.

Yes that IS snow in the background, I love Calgary weather...

Cool patterns when you hold two sheets together. Yes, I could probably be diagnosed with ADD.

This was a test shot before I switched over into the time-lapse mode.

Cutting wheel on dremel. (the pieces I had cut weren't quite the right size... my fault for being rushed when specing out the pieces on the sheet of aluminium)

Clamped the piece down(wood piece to save the metal surface) I wore earplugs here because it can get quite loud, the metal just amplifies the grinding sound.

Bent.

Much nicer day this time, finally some summer.

Explanation time:

I looked into getting 1/2" black acrylic and it was going to be silly expensive so I decided on the next best thing(possibly better?).
My father has access to "scrap" optical-grade clear acrylic at his job and was able to provide me with a few sheets about 2'x3'.
So, I decided to paint the inner-facing side with paint with the hope to create a dark colored mirror-like finish that has some depth to it.

I was going to get the pieces laser cut, but I needed to test out some paints first.

These were the contestants in the paint category. (picked up form Canadian Tire)

The chrome one was mostly for personal interest. I really wasn't sure which one would work better between the blacks though. One is standard black gloss and the other is a "For Plastic" type which I figured should work well.

Turned out the plastic paint was the best.

Blades for the scroll saw.

ready to cut.

The victim.

I just couldn't believe how clear it was when you look straight through it(from an angle there is some crazy refraction).



Super clear!

Pieces cut and ready for painting.

Edges aren't pretty, but that isn't the point here; I'm just testing this stuff.

Masked and ready for paint.

oooooh, Silvery.

Drying... drying... drying...


* This Worklog post was generated using WorklogCreator - Version: 1.0.1.7
* Free Download: http://www.mod2software.com/worklogc...logcreator.zip
Edited by Sparhawk - 7/5/10 at 7:22am

Some shots of the top/back piece where the motherboard will be mounted.



My car... yes it is totally "green"... haha, they don't make 'em like this anymore. 1982 Buick Park Ave. This thing is a tank/boat/awesome-mobile.

On the prowl... (still waiting for paint to dry... really hoping she doesn't shed too much on my pieces as they dry.)

Dry!

Some debris, but this in on the outer layre of 3 or so coats(can't remember how many ).

This is the plastic paint.

This is the regular gloss black.

Chrome. (looks pretty good on this side).

Plastic paint: Very reflective.

Plastic paint: Seriously... really, really reflective.

Plastic paint: A little dirty but again.. that's not the point.

Plastic paint

Plastic paint: The depth gives some neat effects.

Chrome: Looks pretty cool on this side.

Chrome: Not so good on the viewing side.

Chrome

Chrome

Chrome: Not very reflective

Gloss: This side is a little rough looking. (same number of coats were applied with each paint. About 10-15min between coats).

Gloss: quite reflective.

Gloss: Didn't end up being very thick and therefore you can see light coming through.

Gloss

All three side-by-side.

Metal fitting together. Hey! it is starting to look like a case!

Used a sharpie to mark the areas that I will cut out. (this one is for the disk-drive).

I needed some stand-offs and so this kit looked like it had everything I needed.

Also bought short left- and right-angle sata cables.

Ready for dremel cutting.




* This Worklog post was generated using WorklogCreator - Version: 1.0.1.7
* Free Download: http://www.mod2software.com/worklogc...logcreator.zip
Edited by Sparhawk - 7/5/10 at 7:26am

The standoffs were too long. So I trimmed them. Used wire-cutters to take most of the screw off and then used a file for the rest of the way.

Some JB-weld action going on here.

All set. Now they just need to dry.

I/O panel fit! hurray! :whee:

Left-over JB-Weld.





Dry!





Disk drive sans-cover fits almost perfectly. The left side is slightly raised due to the bend in the metal not being a perfect 90-degree corner.

Motherboard mounted.





This stuff is great! (was my first time using it)

Oh snap! Acrylic came back from the laser cutting place. (Laser Equations - Calgary)

I had to send them an AutoCAD file with the measurements. Had issues trying to upload a picture of the CAD file, so we'll go without for now.

Worked out really well... read on to see more shemexy acrylic cut with laser precision.

Front and disk drive pieces.

Top with vents.

Side #1

Side #2

Kitty coming over to check out the shiny new acrylic.

Such nice straight lines. (this is why I decided not to cut it myself... it would have taken me many days to get these pieces cut with edges as straight)

It fits perfectly! :whee: :whee:


* This Worklog post was generated using WorklogCreator - Version: 1.0.1.7
* Free Download: http://www.mod2software.com/worklogc...logcreator.zip
Edited by Sparhawk - 7/5/10 at 7:31am

Make-shift paint booth set up.



Measured the recommended spray distance.

Masked and ready for paint. The masking probably took about 3-4 hours and was a major pain in the butt, hopefully it was not in vain.

I decided to have the tape cover about 1mm on the paint surface to avoid bleeding down the sides of the piece.



First coat finished.

Inside the booth after two coats.

Top after 1 coats.

Disk drive cover after 2 coats

Front after 2 coats

Side #1 after 2 coats

Side #2 after 2 coats

Top after 2 coats

After five coats... i think.





After five coats. The can was very drippy as is evident from looking at the mess near the front of the shroud.

Reflective.

These will be useful for between the acrylic and the metal.

Slowly and carefully peeling off the tape. I was soooo nervous. (disk drive cover)

Disk drive cover - Some bleed through, but not on the edges. This is mostly good!

Looking good so far.

Disk cover

Perfect edge across the teeth.

I was pretty darn happy at this point.

I was pretty much running around the room singing with happiness.

Turned out amazingly well.



Uh oh... a chip! I accidentally knocked this one onto the floor when it was drying. I was hoping it wouldn't have been too badly messed up. One chip isn't bad.

Found another chip.

I knew this corner was going to be bad.

Cracked it a bit, but it was still holding together.

Tossed it together for a mock-up. I was the happiest person ever.

The corner turned out really well. The ribbed texture wasn't part of the design I sent to the laser cutter, but I actually liked how it looked so I didn't smooth it out.



The remains of the masking material. Green tape ftw.


* This Worklog post was generated using WorklogCreator - Version: 1.0.1.7
* Free Download: http://www.mod2software.com/worklogc...logcreator.zip
Edited by Sparhawk - 7/5/10 at 7:42am

bumpers in place and power button holes started.

I used needle-nose pliers to break pieces off.

... then I busted out the precision file.

Almost...

Almost....

...There we are.

Buttons fit perfectly.

Some rubber feet I figured might work on the bottom.

The right side panel piece and the clip that will hold it on.

Test-fitting.

Test-mounting the fans.

Duct-tape in true Canadian style to force airflow where I want it to go.

back-plate with duct-tape treatment.

To attach the acrylic pieces to the metal frame I decided to tap some 6-32 threads.

I used a drill-press to make the holes and then a tap that we had in the shop.

Screws in one of the test pieces.

testing depths.

looks kinda cool.

Front piece getting drilled.

First hole.

Second hole.

I thought the effect was pretty neat and immensely functional

ancient tap tool.

Side view,

With screw.

Installed the front piece. (about 1am at this point... trying to finsh!)

Screws. I actually got really lucky with the front piece because I drilled the holes to line up in good spots on the acrylic and didn't check how the holes would fit with the metal... ...again, I was REALLY lucky they lined up almost perfectly.



Left side piece just about to be drilled.

First hole

Second hole. The acrylic made really cool patterns on its way out of the piece.

The paint was quite thick and seemed to have stuck quite well to the acrylic. Evident with how it stayed adhered to the bits that were drilled out.

Tapped.

Mock-up... getting really close to the finish. :whee:


* This Worklog post was generated using WorklogCreator - Version: 1.0.1.7
* Free Download: http://www.mod2software.com/worklogc...logcreator.zip
Edited by Sparhawk - 7/5/10 at 7:46am

More drilling.



More tapping.

Right side metal piece ready to be attached to the matching acrylic piece.

Notice the little tab on the Right-side piece that hooks on the bottom/front/left-side piece.

Inside view of the front-right.

Top piece marked up.

First hole.

Tapping in action.

Looks good to me.

Beautiful sunset going on when I walked back to the house from the shop.

Lock tab on the top piece at the front.

Close-up of the hook on the Right panel piece.

Also for use as a lubricant....

Fan pegs all lubed up*.

*These little pegs are rubbery and sticky. If you don't lube them up with something they can be a real pain to install.

Fan and disk drive cable installed.

Motherboard ready for some cable lovin'.

Attached the SSD with very advanced electrical tape.

The SATA power connectors that come off the motherboard to power devices were designed by a fool. They were too wide to be plugged in beside a SATA data cable.

Remedy: big file + elbow grease...

Cables all arranged and plugged in.

took a little persuasion but was pretty slick going together.

Not a lot of space, but enough for some airflow.

My high-tech fasteners hard at work again. Twist-ties ftw.

Glue applied to the naked drive.

Used some 5-min epoxy on the drive cover.

Little clear silicone/plastic feet. Blend in almost perfectly here.



Another twist-tie.




* This Worklog post was generated using WorklogCreator - Version: 1.0.1.7
* Free Download: http://www.mod2software.com/worklogc...logcreator.zip
Edited by Sparhawk - 7/5/10 at 7:50am

Completed shots from here on. (A little dusty but it is hard to keep it clean when taking pictures outside.)

It works, plays blu-ray movies and is quiet. I am very satisfied with the results and am glad I was able to share the experience with the OCN community.

Cheers,
~Sparhawk

This one is the case beside my Xperia X10 phone.



Hey who's that guy/camera in all these photos?....



Loving that reflection so much.







Finally done = time for a celebratory beer.











* This Worklog post was generated using WorklogCreator - Version: 1.0.1.7
* Free Download: http://www.mod2software.com/worklogc...logcreator.zip
Edited by Sparhawk - 7/5/10 at 7:52am