[foothead]

Project Ghettobook

4/12/2010 - Plan, laptop disassembly, batteries

7/12/2010 - Keyboard

9/12/2010 - Batteries, part 2

9/12/2010 - New prototype

9/12/2010 - Random parts

15/12/2010 - Batteries, part 3; CF reader

16/12/2010 - Monitor disassembly

19/12/2010 - Cutting plastic, part 1

20/12/2010 - Cutting hinge

21/12/2010 - Dry run

23/12/2010 - Cutting plastic, part 2

23/12/2010 - Batteries, part 4

3/1/2011 - Cutting plastic, part 3

6/1/2011 - Test fitting

20/1/2011 - Palmrest

21/1/2011 - batteries, part 5; parts inventory

26/1/2011 - hinge assembly, attempt 1

27/1/2011 - I/O ports

27/1/2011 - I/O ports (completed)

27/1/2011 - Case assembly, part 1

28/1/2011 - Case assembly, part 2

30/1/2011 - Layout, part 1

30/1/2011 - Case assembly, part 3

3/2/2011 - Case assembly, part 4

5/2/2011 - Hinges, attempt 2

21/2/2011 - Hinges, attempt 3 (plan)

23/2/2011 - Hinges, attempt 3, part 1

23/2/2011 - Front hinges

24/2/2011 - Hinges, attempt 3, part 2

27/2/2011 - Top lid, test assembly

27/2/2011 - Complete case, test assembly

28/2/2011 - Battery control, touchpad, I/O

28/2/2011 - LCD installation

28/2/2011 - Layout, part 2

3/3/2011 - Problem!

4/5/2011 - First successful boot

12/5/2011 - Battery cover

19/5/2011 - Rubber feet, Battery cover

 

[foothead]

Original post:

I think the time has come to begin my GhettoBook work log. The idea is to build a custom LAN rig so I can bring it around between my parents' houses with me. I won't go into details because it will spoil the fun, but here is a hint:

This is a prototype I built out of cardpaper to test my dimensions. The laptop next to it is an apple iBook.

I started with a HP DV7 2270us that I bought from another OCN member. Here's what it looked like when I got it:

It had suffered a mysterious "accident" (seller didn't elaborate) that crushed the screen, broke the trackpad buttons, lost a key, destroyed the HDD, and left huge, deep scuffs on the inside of the case. Perfect for modding.

Here it is when stripped down to just the components I need:

This thing is going to draw tons of juice, so I needed a massive battery. Since nothing appropriate is readily available (at least, nothing that fits my $800 budget), I decided to build my own. I bought two 9-cell toshiba batteries from eBay and two 6-cell external packs from radioshack's clearance, all for $11 each.

Here are the toshiba batteries when opened:

and here is what the inside of the external pack looks like:

I removed the lithium ion cells from all the battery packs, and then rewired them to the charge circuits in the external packs:

First one:

Second one:

Here they are together:

The first pack is 12-cell, and the second is 18-. These will be responsible for powering the monitor, and keeping a charge in the battery for the laptop components. If I can ever get the DV7 battery open, I'm going to add another 16 cells to it.

That's as far as I've gotten right now, but there is tons more coming soon. I'm just waiting for the rest of the supplies to come in.

 

[MR KROGOTH]

Extreme.
That is some awesome battery modding.
+1

 

[DuckieHo]

Did you remove the lithium battery safeties?

If so, be careful since they can exploded.

 

[foothead]

Quote:

Originally Posted by MR KROGOTH Extreme. That is some awesome battery modding. +1

Thanks!

 

[MR KROGOTH]

Quote:

Originally Posted by DuckieHo Did you remove the lithium battery safeties? If so, be careful since they can exploded.

Also, attaching so many batteries to a charger only built to charge 1 pack cant be good, can it? Or will it just charge really, really, slowly?

 

[foothead]

Quote:

Originally Posted by DuckieHo Did you remove the lithium battery safeties? If so, be careful since they can exploded.

Nope, there is a microcontroller to prevent overcharging, and I did not modify the cells in any way.

Quote:

Originally Posted by MR KROGOTH Also, attaching so many batteries to a charger only built to charge 1 pack cant be good, can it? Or will it just charge really, really, slowly?

It just charges really slowly. As long as I don't draw more current than it's rated for, it'll be fine.

 

[ColdRush]

That's pretty insane. I'd rig up a blast shield for the first run.

 

[foothead]

Quote:

Originally Posted by ColdRush That's pretty insane. I'd rig up a blast shield for the first run.

Well, I've already tested the batteries, and they are fine. Actually, they run cooler than before because there are more of them to share the load.

 

[Mygaffer]

Be careful the cops don't see those pictures, they will think another major bomb making operation is going on.

 

[foothead]

Quote:

Originally Posted by Mygaffer Be careful the cops don't see those pictures, they will think another major bomb making operation is going on.

I'm pretty sure the cops can tell the difference between a battery and a bomb...

I ordered lots of random parts for this last night.

It's amazing how much shipping can cost for a $3 cable...

I still have yet to order a HDD or a monitor. I keep hoping something great will come along, bu I rather doubt it at this point. I guess I'mma go with the ASUS MS 248H

 

[Lord Xeb]

Hm... this could be interesting. subbed

This thread is now endorsed by Xeb

 

[luvsan]

Quote:

Originally Posted by foothead I'm pretty sure the cops can tell the difference between a battery and a bomb...

Tell that to the cop that shot a guy, thought he had a grenade. It was a orange.

I'm generally broke so i have to do a lot of ghetto mods. Like if you don't fix it you don't have it. So i respect the hell out of these kinda things.

 

[foothead]

Quote:

Originally Posted by Lord Xeb Hm... this could be interesting. subbed This thread is now endorsed by Xeb

Lol, thanks.

Quote:

Originally Posted by luvsan Tell that to the cop that shot a guy, thought he had a grenade. It was a orange.

Yeah, but that's different. He saw what he thought was a grenade and reacted instinctively. If they see a picture, they would have to figure out who I am and where I live, get a warrant, then send officers out. Totally different scenario there.

 

[Ktmrida4life]

Quote:

Originally Posted by foothead Lol, thanks. Yeah, but that's different. He saw what he thought was a grenade and reacted instinctively. If they see a picture, they would have to figure out who I am and where I live, get a warrant, then send officers out. Totally different scenario there.

And as soon as they read this under your web history, they'll get right on it!

Just messing, nice project. Ill check in every once in a while.

 

[foothead]

Anyone know where I can get laser cutting done? I'm trying to keep costs down, but I really think it'll be necessary for this to turn out well.

 

[foothead]

Got a package from the UPS today.

Rosewill RK-7431

Here's the faceplate removed. I'm going to have to use this as a template for the inner lid so everything lines up.

And here is the keyboard removed entirely from its case.

It's like this thing was designed for modding. The keyboard itself is all mounted to a very thin metal plate, much like a normal laptop keyboard. It also uses a removable ribbon cable, and the indicator lights are separate from the main board so they can be relocated.

BTW, sorry for the huge mess on my desk. That's what happens you've got three major projects going on at once, and only one tiny desk.

 

[foothead]

Finally got the HP battery open to pull the charging circuit. That was total BS, it took me over an hour to get to it, and I completely destroyed the case in the process. Turns out HP had used epoxy to hold the seams shut because they were too cheap/lazy to use a couple screws.

Here's the battery:

Here's what the case looks like:

My ABS sheets came in today. Cutting will probably begin on Saturday.

 

[Capwn]

I die a little inside each time this thread gets updated. ...
lol never the less, keep up the good work

Cant wait till its done

 

[foothead]

Quote:

Originally Posted by Capwn I die a little inside each time this thread gets updated. ...

Lol, sorry about that.

Quote:

Originally Posted by Capwn lol never the less, keep up the good work Cant wait till its done

Thanks.

I've made a few design changes, so I built a new prototype out of the cardboard my plastic sheets shipped in.

Top:

Back:

Side:

Evil doggie does not approve.

And of course, here is a size comparison with a "normal" laptop.

Some of the pieces don't line up properly because the cardboard is 1/4 inch and the design is for 1/8 inch material.