I think it would be a great idea to start off this project with a sort of disclaimer: this project was inspired by the awesome work done by Gtek with his Tenuis and Tenuis 2 projects. Call it a tribute of sorts. The main idea was to build a media player machine for my living room. It was initially based on a Raspberry Pi - a lot smaller than what you guys are building here. However, in the end I decided upon an Odroid XU4. Still small, but more powerful. First step, as always, make a project. Nothing too detailed, as I had a pretty good idea in my head already. Just had to put down some measurements and make everything fit together nicely. Once I had all measurements done and noted down, it was time to get cutting on the raw materials. Cutting was pretty smooth, but I still needed to sand down the edges in order to achieve a good finish. At the end of the day, a test fit was in order. This is when I realised I made some errors in the measurements and I needed to redo the main aluminium plate. With that one redone, it was time to drill some holes for the screws, tap some threads and add mounting posts for the Odroid. All screw holes will be countersunk. I'm using M2.5 screws, 4mm length. Would have wished to hide them, but due to size and material availability I am using 1.5mm sheet aluminium, so I cannot really tap partial threads... without coming out the other side that is. To be continued...
Thanks, Cheapskate! Epoxy would've been a solution, but I don't think it would've afforded me much room for error. Having screws in place means I can do a lot of test fits and get things right in small steps. Having said this, I did take some notes from Gtek's work and I'll use some metal filler and/or epoxy to hide some of the screws and joins which I know I'll never dismantle again. And now, progress! I started by joining the backplate and the main plate together, through a couple aluminum L profiles. That was the easy part. In order to continue, I had to drill the connector holes in the backplate, which I can tell you was a real PITA. Not having a CNC or any similar hand driven machine, I had to drill holes and then file everything until it fit. Came out pretty well, even if not perfect. You can also see the base plate attached to the whole thing. Next up, was the hard drive cradle. Aaaaand, a test fit: Now, time to work on the wooden cover. This will be held in place by an L rod in the front, giving it a little clearing space from the main aluminum plate, and an aluminum profile at the back. Here are the front and side pieces, with the L rod not yet glued together. Epoxy is your friend, on small pieces: Takes a lot of time for that to dry though, so I took the time to drill some holes and install the brass threaded inserts into the wooden parts. Top and front sides glued with brass inserts and hex spacers installed partially: One day later, the L beam was dried and cured, ready for a test fit. Fits rather nicely after a few adjustments, so I can now glue the wooden panels together. Putting together business and pleasure, in a way!
