Case Mod - In Progress Project On The Fly

After scrapping my first mod due to hardware failure, I decided to start another one. This is again just a side project as I save money and gather thoughts and ideas for a bigger project. I like to keep busy but don't want to spend a bunch of money on this project and I'm limited in my selection of tools. Easier said than done as I have already had to buy a new Dremel due to a POS rotary tool already dying on me. Anyway, what I am starting out with was a serious scrap job. An old Gateway P III case that had no side or top panels. So I decided to use the frame and build the whole box out of MDF and a little acrylic.


I'm calling this On The Fly as I am basically coming up with ideas as I go along. I started with the idea to use MDF as it is easy to cut, shape and paint. I also decided to add an acrylic face. It needed some better air circulation as there was only one blow hole for a single 80mm fan in the rear of the case. I will mount a 90mm to the front. So I marked it out....

And began cutting with a crappy rotary tool.....

Dig those Buddy Holly safety glasses I got from my dad.

Cut and some light sanding. I also wanted to cut out the stamped fan grill from the back.

Eventually I'll have to cut out the I/O plate as this one is also stamped into the frame.
As I was working, I forgot to take some pics here and there. This log won't be as detailed as some, but then again this mod won't be as fantastic as Tribals, Cyprios, ModSquads, Darkeneds, etc.. Which I may as well take the time now to thank all the fantastic modders here at Bit-Tech. Without all your inspiration I may have never jumped on such a great hobby. I have always been into art and computers, thanks to you fine folks, I can merge the two.

I cut the front panel from the MDF and marked to blow hole. Time for cutting.

I also marked where the single optical drive will go and be stealthed.

I also routed out the hole a bit to put in some meshing. I will put channel molding around the mesh and when the acrylic front is in place, it will hold it snug.
On the back side I also routed out the opening for the optical drive to help the stealthing.

And that's as far as I got when the rotary tool I had decided to die! (don't even know the brand as the label was missing). I used to have a nice Dremel kit with all the goodies until it was lost in an accident I had at work. I got pics of the truck if anyones interested (lucky to be alive). Anyway, it was time to get a new Dremel.
I picked up a single speed dremel unfortunately as that was all I could justify spending right now. I just started a new job. I will definately get a better one soon, I just hate not having quality tools. I'd rather have less good tools than a lot of junk.

After getting the Dremel, I finished the optical drive opening and test fitted on the frame. Still plenty of clean up and sanding.


I cut holes for the power switch, LEDs and some front USBs. I will also need to cut/drill holes for reset switch and DVD switch, not sure which switches I'll use yet.
I will be using USB ports from a PCI mounted USB bracket. Routed and test fit.


I sanded down the round ends of the LEDs to fit flush behind the acrylic face. I will be using bronzed smoke acrylic left over from my previous disaster. The 'frosted' LEDs should have a nice glow behind the plexi.

I forgot to mention the MDF will be painted black after plenty of primering and sanding and filling of rough spots.
I also managed to get to started on the acrylic piece for the front.

My weekends are my visitation time with my sons and this weekend was the company picnic. Tomorrow I am off, so hopefully I can get some more done worth an update.

 

On the Fly

 

can't wait for the progress, projects made just as they go are sometimes the best !! I hope it will be like this with your one.

 

I ended up working a few hours today on a small side job installing some radiant floor heat plumbing.So just a small update for today.

I cut out the stamped I/O panel...

...so I could fit replaceable panels.

I also cut the top panel for the case and drilled the holes to secure it to the frame.

I drilled wells for the hex head bolts as I didn't want them to protrude.

Yeah, it was one of those OOOPPS days.

But the nice thing about using MDF is all you have to do with something like this boo boo is fill the hole. I had marked a couple of different spots for the bolts, I just drilled the wrong one the first time.
I also made some more cuts in the acrylic front panel. I peeled off the masking to get a better look and feel for what I was doing, Plus I didn't want to leave the masking tape on too long, it's not the good stuff and has short work time. It already showed signs of leaving residue. You can also see the mesh I added for the blow hole. Things still need to be tweaked.


I can't seem to find my files anywhere. I don't know what the hell I did with them...... So I'll have to get looking harder or end up buying a new set. I'm still waiting on an order as well, so the most I'll get done until then is probably the other panels and some sanding and priming/painting.

And now for something completely different.....

 

sweet front panel!

 

Need some advice. I need a good place to get momentary switches. I want something small for the optical drive and reset, but most I have found are kind of lackluster. Mostly plactic buttons and they stick out much to far. I want something like the bulgin, but smaller.
Also, do you think I should add another fan to the front, it seems like a rather bare area that could be used or maybe increase the hole and use a 120mm fan instead?
Thanks all for taking a peak and any advice is appreciated.

 

Dead VCR's are a good source for surface mount tactile switches.
You could always hide the ugly switches behind a marble like I do.

 

SPQQY - first what i wanted to say .. yeaah 120mm isa a good idea, about switthes ... how about making the same as i did... radio controlled ON/ff and reset its easy and very comfortable. (yeah i'm lazy a bit) but think about boring and exhausting day at work u're getting back to your home and before U enter your house u just push the rc button... and when you will finally sit near your computer it will be ON. In case the RC will broke U can make buttons in the back side of case they won't be visible.

 

Thanks for the info, guys. I'll have to remember those tips. However, I found this little guys which will work out perfect. And they were only a few dollars for the two of them (you got nothing on me Cheapskate....LOL).

I had the day off and got a little done, but not much as I have been busy with my dog. He's 16 years old and I've kept him going for a while as he has been diabetic for 6 years. I can't seem to keep his sugar/glucose regulated anymore and he's been sick and I simply can't afford to do more testing. He's been a good pet and friend of the family, but I think he is suffering too much now and it's time for the big sleep.

BTW, HeXen, only girls are aloud to call me Spooy.......

 

the mdf front panel... WOw! paint turned out awsome

Eager to see the front switches XD

 

Hey Teyber, thanks for dropping in. How's the vacation? Actually, the front panel you see is the acrylic front. The mdf is the backer and I haven't painted it yet. Had to get all the cuts worked out first.

 

I got some nice switches at http://www.sunshinele.com/htm/pushbutton_switch.html
Datasheet for the ones I got: http://www.sunshinele.com/down/as2gq.pdf

They're somewhat smaller than the bulgins and a lot cheaper.

 

You ordered from China? How was shipping cost?

 

man, i can't wait to see your "big" project... i put "" because the ones your working on now are incredible! especially considering your tool situation! im nothing short of impressed/amazed at both this and b io-mec...

keep it up!

 

Didn't see this earlier;

I opted not to use express shipping; so they didn't charge me extra for shipping (but they shipped DHL express anyways )
The switches were ~ $3.25 each; I got 7 for ~$23, if I had selected express it would have been an additional $58 (but would still have been cheaper than ~$20/bulgin)

Also, I was able to get latching switches, which Bulgin doesn't have available yet.

 

Well, I actually went to do some work on this tonight, I was waiting for some putty to dry on Bio-Mech. I have a back room on the garage where I had the pieces for On the Fly leaning against the wall. We've had the rainiest month in over 17 years here and guess what, there was enough water built up behind the garage to go over the 8 inch foundation and leak into the back room. It soaked two of the four panels. My once 1/2 inch mdf is now 3/4 inch on one side......LOL.


But I have more than enough to do on Bio-Mech to stay busy and I have a better idea for this one that doesn't involve mdf and I can salvage the acrylic part of the front panel make it look even better. But I'm too deep into Bio-Mech now to worry about this one.

 

man, this one is looking good, so i hope to see this finished eventually!
any idea of what the side panels wouldve been like?

 

Wow this is really nice I love the work! You doing nice job here, Well done. I love that switch heheh

Good luck