Project: Air Force One (Last Update: 01/18/06)

Project: Air Force One
--------------------------------------------------------------------------------

UPDATES:
-------------------------------------------------------
- Update (12/19/05) - First Attempt at Fan Grill
- Update (12/19/05) - Making a Modular PSU
- Update (12/20/05) - Making a Modular PSU (Part 2)
- Update (12/20/05) - Making a Modular PSU (Part 2) Cont.
- Update (12/21/05) - Making a Modular PSU (Part 3)
- Update (12/23/05) - Finish PSU and Start on Front Bezel
- Update (12/27/05) - Front Bezel and Touch Switches
- Update (12/29/05) - Front Bezel (Part 2)
- Update (12/31/05) - Front Bezel (Part 3)
- Update (12/31/05) - Front Bezel (Part 3) Cont.
- Update (01/01/06) - Front USB Ports
- Update (01/04/06) - Relocating DVD LEDs
- Update (01/08/06) - Wiring Front Bezel
- Update (01/10/06) - Remaking Modular PSU (Part 1)
- Update (01/10/06) - Remaking Modular PSU (Part 1) Cont.
- Update (01/18/06) - Remaking Modular PSU (Part 2)


About a year ago I modded a generic Antec/Chieftec case. This included cutting a window in the side panel and top, painting, a simple etch in the window and some ccfls.

Here are some pics of the case as I have had it for the past year:






Since then I have upgraded the computer inside but I have kept the case. I have always wanted to mod it more and now that I have a chance over Christmans break, I am going to add a few things.

So far I am planning the following:

- Mod PSU into modular style, sleeve PSU wires, add black molex connectors.
- Add 4 blue LED fans
- Cut fan hole in side acrylic window for one LED fan, fabricate custom fan grill
- Build two circuits for touch sensitive switches to be used either for optical drives or power buttons
- Modify front bezel of case to stealth drives, relocate power buttons / LEDs and drive buttons / LEDs (If I have time)
- Add additional etchings to the case panels (on the steel) (If I have time)

Any comments and/or suggestions would be greatly appreciated.. The discussion thread for this project can be found HERE.

Thanks !! And enjoy !!

 

Project: Air Force One Discussion (Last Update: 01/18/06)

This is the discussion thread for my current project Air Force One.

The project log can be found HERE .

Project: Air Force One
--------------------------------------------------------------------------------

UPDATES:
-------------------------------------------------------
- Update (12/19/05) - First Attempt at Fan Grill
- Update (12/19/05) - Making a Modular PSU
- Update (12/20/05) - Making a Modular PSU (Part 2)
- Update (12/20/05) - Making a Modular PSU (Part 2) Cont.
- Update (12/21/05) - Making a Modular PSU (Part 3)
- Update (12/23/05) - Finish PSU and Start on Front Bezel
- Update (12/27/05) - Front Bezel and Touch Switches
- Update (12/29/05) - Front Bezel (Part 2)
- Update (12/31/05) - Front Bezel (Part 3)
- Update (12/31/05) - Front Bezel (Part 3) Cont.
- Update (01/01/06) - Front USB Ports
- Update (01/04/06) - Relocating DVD LEDs
- Update (01/08/06) - Wiring Front Bezel
- Update (01/10/06) - Remaking Modular PSU (Part 1)
- Update (01/10/06) - Remaking Modular PSU (Part 1) Cont.
- Update (01/18/06) - Remaking Modular PSU (Part 2)



About a year ago I modded a generic Antec/Chieftec case. This included cutting a window in the side panel and top, painting, a simple etch in the window and some ccfls.

Here are some pics of the case as I have had it for the past year:






Since then I have upgraded the computer inside but I have kept the case. I have always wanted to mod it more and now that I have a chance over Christmans break, I am going to add a few things.

So far I am planning the following:

- Mod PSU into modular style, sleeve PSU wires, add black molex connectors.
- Add 4 blue LED fans
- Cut fan hole in side acrylic window for one LED fan, fabricate custom fan grill
- Build two circuits for touch sensitive switches to be used either for optical drives or power buttons
- Modify front bezel of case to stealth drives, relocate power buttons / LEDs and drive buttons / LEDs (If I have time)
- Add additional etchings to the case panels (on the steel) (If I have time)

Thanks !! And enjoy !!

Please post any comments / suggestions !! Thanks for looking and enjoy !!

 

Update (12/19/05) - First Attempt at Fan Grill
--------------------------------------------------------------------------------

Well in between studying for finals last week, I decided to start working on the fan grill that I am going to make from scratch. I have an Air Force theme with this computer so I was looking for something appropriate. I decided to use the JSF (Joint Strike Fighter ) logo.

So I found a template for a 80mm fan (since I didn't have my LED fans yet), and with a little photoshop work, came up with this:


I cut it out using a coping saw and then filed it down. I ended up breaking one of the wings so I cut the main plane out of a piece of aluminum and then etched both the plexi and aluminum.



I glued them together and I'm done... right ?




Wrong ! The template was not the correct size so the grill was too small. All that work for nothing!!

So I remade the template with a few minor changes after verifying it was the correct size and followed the same steps for cutting it out.




Am am still currently filing it down and I will post final pics when I'm done. I am being careful not to break it like I did the first one.

Please post any comments / suggestions !! Until next time !!

 

Update (12/19/05) - Making a Modular PSU
--------------------------------------------------------------------------------

I know I could buy a modular PSU for a reasonable price, but then I wouldn't have the fun of modding my current PSU! The main reason I want to do this mod is to clean up the wires and make the inside of the case look a lot cleaner. As you can see in the first post, my wires have been very messy and I am looking to change that.

The original PSU:


Dismantled:


In order to mount the connectors in the PSU, I have to extend it out a little. I am going to do this using aluminum C-channel stock.

Aluminum pieces cut to length:


Sanded to a 45 degree angle:


The pieces form a frame for the extension:


Epoxied together:


Template for connector locations:


Holes cut and filed to correct size. The connectors are just resting in the holes:


Faceplate resting on the aluminum frame:


In order to make it easier to route the wires within the PSU, I need to cut a hole in the original side to allow more room. I used the same template for the rough cut.



I then epoxied the aluminum frame the PSU case:



I then tapped four holes in the new aluminum expansion section so I can connect the acrylic faceplate.



The faceplate attached to the PSU:


I need to run to the hardware store tomorrow to grab some small screws to attach the DIN connectors to the faceplate. Also, I need to paint the aluminum expansion section black to match the rest of the PSU and I need to decide what I should do to the acyrlic faceplace. I am trying to decide between frosting the plexi and adding a few LEDs behind it, or just painting it black and just have the LEDs shine through the fan hole. Until next time...

Any comments or suggestions would be appreciated.

Thanks for looking!!

 

Always nice to see someone using the old school cheiftec case
While your at it, consider chopping out the mesh over the front and back fan holes, it makes them noticably quieter...

 

mods comeing along great i like what your doin to the psu tempted to do it to mine

 

I think I might do that. I am adding more fans but I don't want it to be very loud. The front mesh shouldn't be a problem to cut out and leave it that way. But for the rear, I don't want my cat or dog getting caught in the fan. Would replacing the mesh with a less restrictive grill help with the noise? Thanks for your comments!

Thanks! Ya, I have been wanting to mod my PSU for a while in order to clean up all the messy wires in my case. So far so good IMO. Thanks for your comments!

 

Nice fangrill

The psu modular mod is nice

 

Thanks !! Hopefully both turn out well! Thanks for your comments!

 

i really like the grill youve done, its little details like that that personalise the case more to your self is great. and if someone see it and realises it was done by hand by your self they will know how much work went in to that. and you did it with a coping saw. i take my hat off to you sir

 

Im very impressed, you are practicly rebuilding your PSU.

very nice work so far.

 

Really nice to see some PSU modding

Good luck!

 

Looks nice. I'm keeping an eye on this. Especially your fan grill. Too bad about the first one but I would do the same thing to the second one. Cut the plane out of aluminum and place it on the grill. It gives it some depth.

 

What kind of connetcors did you use? link?

 

Update (12/20/05) - Making a Modular PSU (Part 2)
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Well I spent most of today working on the PSU. I wanted to get as far as I could tody so I can hopefully finish it tomorrow and move onto other parts of the case.

I started off by priming and painting the PSU extension section that I made.

Primer:


Paint:


I also painted some screws for the faceplate:


While I was waiting for the paint to dry, I followed phuzz's suggestion about cutting out the front fan mesh to make the fans run quiter:



Here is the PSU all painted and pretty:


I decided to go ahead and frost the faceplate and put LEDs behind it. I used glass frosting to get the desired effect:


I purchsed 5 80mm LED fans from xoxide.com. Although I originally wanted to buy blue LED fans, they had a deal on white LED fans that were mislabeled as UV for only $1.99 each. I decided to get these and then just switch out two of the white LEDs for blue and get about the same effect for a few bucks cheaper.

80mm fans:


Mislabeld as UV:


I swapped two of the white LEDs out of one of the fans and replaced them with blue LEDs.

I then wired the two white LEDs that I removed and two blue LEDs to be put into the PSU. I will be powering these off of the 5v rail of the PSU:


LEDs mounted in PSU case:


Once the LEDs were mounted, I begin preparing to cut all of the wires. The biggest hassle was the ATX motherboard connector.

I labeled all of the wires before I cut them:


CUT!!


Faceplate on PSU.. I think it came out well!


I originally was going to mount a black ATX power connector on the faceplate, but I realized that I didn't have enough pins to do that. So I ran to the local computer supply store and just bought a standard 25-pin D-Sub connector and pins. It should work just as well.

ATX D-Sub Connector wired up:


I then started wiring up the remainder of the connectors. I am using DIN connectors that I bought from Action Electronics:

 

Update (12/20/05) - Making a Modular PSU (Part 2) Cont.
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All wired up:


All the connectors pushed in:


As you can see, there are a lot of wires inside the PSU case. There is not very much room in there!


Now I was ready to test out the PSU. I was half expecting it to start smoking so I didn't want to connect it to my computer. So I used a jumper to just see if it would turn on. And to my delight, it turned on without any problems on the first try:

With lights on:



With lights off:


As you can see, I used the two left over white LEDs from the fan and two blue ones. I am very happy with the results. I think it turned out very well. Tomorrow, I need to screw all of the connectors down, put the fan back in, and then make all of the cables. Hopefully I can completely finish the PSU tomorrow and move on to something else.

Any comments or suggestions would be appreciated.

Thanks for looking!!

 

Thank you! It does take a long time to get all of the details, but that is what makes it so fun. Knowing that you made it by hand is very satisfying.

Thanks! I have had the idea to do this to my PSU for a while, we'll see how it turns out.

Thanks! Hope it turns out okay !

Thanks! Ya, now I know to ALWAYS measure before you cut. I am not sure if I am going to do the plane out of aluminum again, but I might. I do like the way it looked. We'll see when I get there I guess.

I am using DIN connectors (not miniDIN) that I purchased from Action Electronics. The main reason I chose these connectors becuase I think they look cool and they are cheap!

 

nice work on the psu, might do that to my own soon

 

Nice PSU mod.
KUTGW

 

Thanks !

Thanks !