1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Scratch Build – In Progress Project: Small Moderately Audible HTPC

Discussion in 'Project Logs' started by crazylittleman, 24 Feb 2007.

  1. crazylittleman

    crazylittleman What's a Dremel?

    Joined:
    13 Sep 2006
    Posts:
    59
    Likes Received:
    0
    [​IMG]

    Hey all.
    The idea here is a all aluminium HTPC based on laptop drives, mATX motherboard and a shuttle PSU.
    [​IMG]
    The panels will be 2mm aluminium araldited and riveted to a frame made from 12mmx12mmx1.4mm L rail aluminium.
    In terms of hardware im looking at a athlon XP/P4 underclocked with one 120mm fan over the headsink exhausting air out of the top of the case.

    Drive Cage
    The laptop HDD and DVD drive will be mounted in a frame made from .5mm sheet aluminium joined with araldite, 3mmx30mm flatbar aluminium and 12mmx12mmx1.4mm L rail aluminium (same as the frame).
    [​IMG]
    I printed a template from sketchup and glued it using spray adheasive onto .5mm aluminium. Then cut it out using a jigsaw and tinsnips.
    [​IMG]
    Next I bent the sheet aluminium in a benchvice.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
    Last edited: 18 Apr 2008
  2. Supra55

    Supra55 What's a Dremel?

    Joined:
    10 Oct 2006
    Posts:
    423
    Likes Received:
    0
    Looks pretty good I like the idea, but that metal looks a bit flimsy.
     
  3. TapperSwe

    TapperSwe What's a Dremel?

    Joined:
    20 Nov 2006
    Posts:
    254
    Likes Received:
    0
    U got some serius Alubending going on there ,this should be interesting.
     
  4. Kipman725

    Kipman725 When did I get a custom title!?!

    Joined:
    1 Nov 2004
    Posts:
    1,753
    Likes Received:
    0
    if your getting the athlon XP for low power consumption consider getting a sempron 754 chip instead there about the same price, and as far as my experiance goes use alot less power.
     
  5. Jipa

    Jipa Avoiding the "I guess.." since 2004

    Joined:
    5 Feb 2004
    Posts:
    6,364
    Likes Received:
    125
    You don't need 56k-warning in a project log, instead you can use the space to tell when the last update has been done :)

    The sketches look interesting, silent computers are always nice!
     
  6. crazylittleman

    crazylittleman What's a Dremel?

    Joined:
    13 Sep 2006
    Posts:
    59
    Likes Received:
    0
    @Supra55: At first the alu is very flimsy but once I bent it and added the thicker aluminium joining pieces it becomes quite strong.

    @Kipman725: Yeah when i said Athlon xp it was more of a guess, Its all going to depend on waht i can find cheap. As well as what type of motherboard i can find in mATX size.

    [​IMG]
    Once the glue dried on the drive mount I cleaned all the excess glue up with 600wet&dry sandpaper then test fitted the drives.

    Exhaust Fan Mount

    [​IMG]
    The Exhaust fan mount is made from the same .5mm aluminium as the drive mounts. It was cut using a sketchup template the same as before. At first the aluminium was very weak so I've bent 5mm sections of the edge to give enough strength to support the weight of the fan.
     
  7. Supra55

    Supra55 What's a Dremel?

    Joined:
    10 Oct 2006
    Posts:
    423
    Likes Received:
    0
    Looks good.
     
  8. hellas91

    hellas91 What's a Dremel?

    Joined:
    18 Feb 2006
    Posts:
    93
    Likes Received:
    0
    I like the case,simply and clean
     
  9. douphus

    douphus What's a Dremel?

    Joined:
    26 Aug 2004
    Posts:
    127
    Likes Received:
    0
    you should go to onlinemetals.com and order yourself some thicker aluminum panels. it'll look better. otherwise the design is nice.
     
  10. crazylittleman

    crazylittleman What's a Dremel?

    Joined:
    13 Sep 2006
    Posts:
    59
    Likes Received:
    0
    Yeah the .5mm alu is just for the internal mountings, the outside panels will be 2mm thick alu for the top, base, sides and back with 3mm alu for the front.
     
  11. Tulatin

    Tulatin The Froggy Poster

    Joined:
    16 Oct 2003
    Posts:
    3,161
    Likes Received:
    7
    How're you printing that well from sketchup, and to scale?
     
  12. crazylittleman

    crazylittleman What's a Dremel?

    Joined:
    13 Sep 2006
    Posts:
    59
    Likes Received:
    0
    The Sketchup templates can only be made in Sketchup 5 not Google Sketchup
    To make them I first make tke 3D model im trying to create.
    -Next I have to manually go through the model and make a copy of each of the outside surfaces.
    -Then line the copyed surfaces up into a flat template.
    -Select the print menu and set the print scale to 1mm:1mm.
    -Then print them with a standard desktop printer.
     
  13. JAxen

    JAxen What's a Dremel?

    Joined:
    18 Nov 2005
    Posts:
    243
    Likes Received:
    0
    Nice bendin on that cage :)
     
  14. crazylittleman

    crazylittleman What's a Dremel?

    Joined:
    13 Sep 2006
    Posts:
    59
    Likes Received:
    0
    Base panel/frame

    [​IMG]
    The motherboard will be mounted on screws though the bottom of the case. This allows the motherboard height to be adjusted to get the best fit with other components.

    [​IMG]
    The mounting holes are drilled from a sketchup template.

    [​IMG]
    The frame is then cut to fit the panel and attached with araldite and rivets.

    Side Panel

    [​IMG]
    The side panel is first sandwiched between two pieces of 3mm MDF and clamped, next the template printed form sketchup is overlayed on the MDF. I think drilled 1/8 pilot holes then finally 5.5mm vent holes.
     
  15. crazylittleman

    crazylittleman What's a Dremel?

    Joined:
    13 Sep 2006
    Posts:
    59
    Likes Received:
    0
    Backpanel

    [​IMG]
    The expansion cards are designed to be kinda tool less. The top of the card bracket sits in a slot about the cardports, it is then held in place by a piece of 20x3 flat bar alu with notches cut out of it.

    [​IMG]
    I copied out a template then scored it into the metal with a knife. Then cut out each piece with a jigsaw.

    [​IMG]
    The cuts were straightish but will require a bit more filing when i put it all together.
     
  16. crazylittleman

    crazylittleman What's a Dremel?

    Joined:
    13 Sep 2006
    Posts:
    59
    Likes Received:
    0
    Side Panel

    [​IMG]
    The original plan was to make a vent using a series of slots cut using a drill press and jigsaw.

    [​IMG]
    Well that didn't work to well. I couldnt get straight slots using a template.

    To correct this I cut a piece of .5mm aluminium sheet, clamped it between two 19mm chipboard pieces then overlayed a sketchup template.
    [​IMG]

    [​IMG]
    I then used a drill press to drill 5/13 pilot holes then 5.5mm vent holes.

    [​IMG]

    [​IMG]
    Original 2mm panel cut to fit.(still needs to be glued)
     
    Last edited: 18 Apr 2007
  17. Duste

    Duste Sierra my delta, bravo!

    Joined:
    1 Oct 2006
    Posts:
    818
    Likes Received:
    0
    That DIY mesh got pretty warped. :|
     
  18. jezmck

    jezmck Minimodder

    Joined:
    25 Sep 2003
    Posts:
    4,456
    Likes Received:
    36
    thicker sheet shouldn't get so warped.
    alternatively, get some mesh from elsewhere and put that inside a frame which you make.
     
  19. jezmck

    jezmck Minimodder

    Joined:
    25 Sep 2003
    Posts:
    4,456
    Likes Received:
    36
    I think you may have an easier time with SU6 and its new Template feature, but I've not yet tried it out.
     
  20. crazylittleman

    crazylittleman What's a Dremel?

    Joined:
    13 Sep 2006
    Posts:
    59
    Likes Received:
    0
    Does sketchup 6 have a seperate template feature? I tried it and could only print perspective shots (same is google sketchup), i couldnt find any print to scale options?
     

Share This Page