Scratch Build – In Progress Project: Half-Life 2 Supply Crate Rackmount

I probably should have said this earlier but most of the design of the crate is modeled after an a/v flight case which are mostly wood see - http://www.bhphotovideo.com/c/product/443771-REG/Anvil_AN2518R8_AN25_18_Escort_8_Space_Rack.html If it needs extra support, I'll reinforce the corners inside with metal but I'll wait and see for now.
When the case is in use, the front and back panel will be removed. I want to be able to show the hardware off. I would like to do some sort of bezel on the 2u cases in uv acrylic that will glow under uv.

I'm spending this weekend upgrading my desktop and farm to 64bits... Hopefully...

More modding on Monday....

 

very detailed project.keep it up.

 

Just a small update.
I got the hole for the power supply cut. The scroll saw was perfect for this cut. I predrilled holes in the corners to make the turn a little easier and then I unfastened the bladed and feed the blade through one of them.

 

Well this has been another busy week but today I was able to get a lot done
First I got the rest of the pieces for the 2u cases prepped

I got those pieces cut just like in my last update.

Next onto the bottom of the 2u cases. I cut the pieces on the table saw out of masonite.

I want the motherboard standoffs to be grounded like they are in normal case so I cut a piece of aluminum flashing.

Finding a glue that will bond wood to metal is a bit of challenge. Since I'm trying to bond two flat things together, Spray adhesive was the best choice. Spray adhesive is nasty smelling stuff and so its off to the paint room which has a vent hood.

For a permanent bond you coat both sides and wait 30 seconds

Then I flipped the metal over and pressed any air bubbles out.

Next up, putting the 2u cases together....
First i glued and clamped the corners together

And then I reinforced them with some brads


But I got the first 2 almost done.

They still need the front panel which will connect those pieces to the rack. I haven't glued them on yet because they will be finished much nicer.

 

looking nice so far... could definitely do with some woodstain/sanding sealant to darken it though

 

Ah It's all starting to come together now.
First I got the 2u Face Pieces Primed


Then they got a nice coat of Black Satin

I got the rest of the plywood for the crate cut and all the pieces fit together nicely

The front and back panels will be removable to show the rack. Here you can see where the rack will be. I have the template on the plywood.

This one's to big for the scroll saw, I had to use a Jigsaw this time. The 1/4" plywood is to thin (and weak) to hold the rack mount rails so i cut some supports out of 3/4 ply.

and then I screwed the rails to 3/4 peices

Now It's time to glue, nail, and screw this thing together.

 

I like this build.
Gives me some ideas for my own two PCs which should go on the underside of a table.

 

are you going to paint on the supply thing that's on the real box in hl2?

 

I would like to eventually. I might change the text to read computers instead of heath kits and the weight to 60 instead of 30. (see this image if you never noticed the text before)

 

oh, never actually read the text (on my old pc the textures have to be low)

 

great idea

I think it would be sweet to change the text to computing terms, if you can keep that stencil look, maybe add up your ram, your hd space, network speed, cpu, power wattage, etc.

and if you really wanted to geek out, you could modify the supply barcode to read what you want. I did a quick search on barcode generators, and there's a few online. You may have to figure out an image transfer system if you wanted to be exact and able to be read. Here's an example from http://www.terryburton.co.uk/barcodewriter/generator/


This is my first image share attempt, so let me know if doesn't work please!

 

Ah, time for an update.

Well the crate almost got done in time for the LAN Party.

So with the front rails done, I put the top and side panels around it and nailed, glued and then reinforced the main joint with screws.


I flipped it over to put the bottom on. The wood shop closed before I could get the back of the rack cut out so in the picture below it's just being held in place with friction.


To hold the bottom on, I used a bunch of screws that went into vertical slats that are on the sides and the vertical reinforcements behind the faceplate of the rack.


Ah, The crate is almost done. All if the 2u cases fit nicely. I also did a mockup of what I want the vent covers to look like.


Onto the rails.. I cut some 16.5 x .375" x .75" pieces of plywood


I cut similar pieces for the 2u cases and glued them on.


Next up the interior of the 2u cases. I printed out a template for where to drill the holes for the motherboard


Next update will be on the interior of the 2u cases....