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Scratch Build – In Progress LanAmmoBox

Discussion in 'Project Logs' started by s0lid, 21 Mar 2012.

  1. s0lid

    s0lid Dremel? Hacksaw!

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    First time this idea came to me when mini-itx Via Epias were the only brand on that segment and Athlon 64s something brand new. But now the situation is changed to better direction, mini-itx boards have became affordable with wide range of cpu sockets to choose from and most importantly proper slots for GFX card. Since local military goods shop (varusteleka) got these NATO .50cal ammoboxes in stock again I decided to throw together a compact and durable machine for Lan Partying.

    --The plan/goal
    -Fit lanbox into NATO .50cal Ammobox (id: 27.8x14.4x17.5cm LxWxD)
    -Build a insert for the parts from 1.5mm steel sheet
    -I/O will be facing up, since lid of the ammobox is easily removeable
    -Not a single change to the Ammobox itself

    --HW
    -A8-3850
    -Asrock A75M-ITX
    -Powercolor HD7750
    -8GB DDR3
    -2TB 3.5" Samsung HDD
    -2.5" SSD (tba)
    -BQT 350W SFX psu the s0lid edition
    -Noctua LH-N12 in single fan mode + 2-3 60x60x25mm fans
    -Pci-e x16 flexriser

    --Todo list@23.03.2012
    -Cut 2-3mm extra from the bottom of insert -> fits deeper -> more space for i/o and face plate under the lid and the gasket.
    -Bend face plates mounting flaps.
    -Smoothen and paint the insert so it doesn't look like it has been forget with a hammer (which it is :D).
    -The face plate

    --(Crappy) pictures

    [​IMG]
    The box.

    [​IMG]
    Results of Day #1, the insert pretty much cut into shape and most of the mounting holes are done. Everything is fixed to the steel with m3 self-clinching nuts (drill a hole, insert nut into it and apply ~2tons of pressure).

    [​IMG]
    Hdd mount. Chopped lian li hdd tray and some angled aluminium.

    [​IMG]
    Nothing extra ordinary here. Just testing that the board fits with the holes.

    [​IMG]
    The psu. All the C(r)apxon capacitors have been replaced with proper NC KZE series caps exculding one tantalium cap and the mains capacitor (also NC but different series ofc). Cable shortening/removal inc...

    Tomorrow will be fun, gotta do the bends. Which are highlighted with red in the following picture.
    [​IMG]

    Those already installed S.C.Ns cause some consern and it's not really possible to install them after doing the bends (only got this big 20 ton hydraulic press -> flat sheet only).

    Those little flaps with S.C.Ns are used for mounting the face plate which will hold the GFX card inplace, power connector, intake and exhaust fans, power button and i/o shield. The face plate itself will be made either from the very same steel or aluminium.

    Reason why this is Scratch Build: There will not be any mods done to the ammobox itself which will simply be the outer shell and everything else is built from scratch.
     
    Last edited: 24 Apr 2012
  2. fr0Zen

    fr0Zen sabertooth 990FX

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    i wan't one now!:rock: I've been thinking about all the awesome things you could do with ammo boxes.
    mod on :dremel:
     
  3. s0lid

    s0lid Dremel? Hacksaw!

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    Small update.

    Test fit after bends, the fit is tight... Too tight actually had to use small sledge and piece of wood to get insert in there.

    [​IMG]

    [​IMG]

    Now i gotta get that outta there, some how and make it fit better :p
     
    Last edited: 22 Mar 2012
  4. Cheapskate

    Cheapskate Insane? or just stupid?

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    Um... If you had to take a hammer to it, it didn't really fit. -You made it fit.:hehe:

    I like ammo box rigs. I really like ammo box rigs that can still be waterproof.:thumb:
     
  5. s0lid

    s0lid Dremel? Hacksaw!

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    Spend 1-2 hours alone hammering the insert so it now slides in and out with ease without being too loose.

    Yeah the case will be waterproof when lid is closed :p

    Also new pic.

    [​IMG]

    The bends look excatly that rough on every side atm :D
     
  6. s0lid

    s0lid Dremel? Hacksaw!

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    Small update once again.

    [​IMG]
    SSD mounts done.

    Todo list: (goin to copy this to first post)
    -Cut 2-3mm extra from the bottom of insert -> fits deeper -> more space for i/o and face plate under the lid and the gasket.
    -Bend face plates flaps.
    -Smoothen and paint the insert so it doesn't look like it has been forget with a hammer (which it is :D).
    -The face plate
     
  7. novaris

    novaris New Member

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    bookmarked..

    i had planned on doing this when i saw some old ammo boxes for sale but i was already working on another project.
     
  8. spolsh

    spolsh Active Member

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    nice idea, hope it works out as planned.
     
  9. s0lid

    s0lid Dremel? Hacksaw!

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    Already chopped off 2mm from the bottom of the insert but looks like i can still take off another 2mm :)

    [​IMG]

    At the moment insert fits to ammobox so that it's about 1.5mm below ammobox's edge.
    Which is still too high because the gasket and how the lid is built.

    [​IMG]

    the imprint from the edge is about 1mm deeper than rest of the gasket and when lid is closed the mechanism presses edge of ammobox about 2 mm into the gasket. So there's really like 171-172mm of space at the edges when the lid is closed.

    Also minor problem. I gotta remove the cooler when I got to remove or install the board..

    [​IMG]
     
  10. s0lid

    s0lid Dremel? Hacksaw!

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    Moved the psu mounts 1 cm to the center.

    [​IMG]

    [​IMG]

    Also forged that side a bit so the inserts fit is pretty much perfect.
    The long side does not bend any more when put into place and the whole insert is easier to remove.
     
  11. s0lid

    s0lid Dremel? Hacksaw!

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    Month later... Updates!

    [​IMG]
    The insert is pretty much cut into lowest possible shape. The gasket on lid does not hit the edges or i/o ports and there's maybe 0.5-1mm space between edge of mobo and bottom.

    [​IMG]

    [​IMG]
     
  12. Cheapskate

    Cheapskate Insane? or just stupid?

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    You got me wondering if you can fit ITX/PSU/ssd in the next size down ammo box. It looks very doable.
     
  13. Cown

    Cown Member

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    This is pretty awesome, looking forward to more :D
     
  14. s0lid

    s0lid Dremel? Hacksaw!

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    The 30. cal one?
    I think that's too small for this, it's only 26x16.5x5.8cm LxHxW.
    E: Did some digging as Varusteleka says the .30cal is 26x16.5x5.8 but elsewhere I found different size which is 28x19x8.9cm. That indeed is doable with ease :)
     
    Last edited: 24 Apr 2012
  15. s0lid

    s0lid Dremel? Hacksaw!

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    Started working on the front panel.
    [​IMG]

    Fit is perfect but the lid won't close wanna quess why?
    Shortest distance in the lid is 146mm, so is the shortest distance for the outside for the ammobox.
    The edge is of that front panel is made to fit there when the lid was not closed. Now the distance at the middle of the ammobox is around 148mm.
    Looks i gotta remove 1mm on the both sides of that front panel to get the lid to close :)
     
  16. s0lid

    s0lid Dremel? Hacksaw!

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    Small update: I/O plates hole is done :)
    [​IMG]

    That is 1.5mm aluminium btw.
     
  17. s0lid

    s0lid Dremel? Hacksaw!

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    AC inlet and exhaust psu fan.
    [​IMG]
     
  18. s0lid

    s0lid Dremel? Hacksaw!

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    Little over a month later, after moving out and being employed about 600kms away from every possible tool:
    [​IMG]

    Re-take on the plate that'll will hold every possible fan and other thing; ac inlet, power button, gfx card (you'll see) etc.
    Got still tomorrow to work on this. Next time will be be before assembly summer '12 so i can get this finished for the party :)
     
  19. s0lid

    s0lid Dremel? Hacksaw!

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    Little update for today.
    Did the gfx mounts, power_on button hole and psu rf/emi shield.

    [​IMG]
    gfx mounts.

    [​IMG]
    power button and little bit of psu rf/emi shield.

    [​IMG]
    Inside shot from rf/emi shield. The shield is mounted from the sides with 4x m3 screws.

    Next update will be in next month, as it's not cheap to travel 600kms and back :|
     
  20. warboy

    warboy Insane modder

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    great idea! brilliant!
     

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