Media center MOD

[iCer]

I started out with an old 3ghz Intel which I brought cheep of a friend.
Didn’t know what to do with it until for a while. I then though I’d use it for a media center PC to connect to my 42” rear projection screen TV.

The case started very basic, and I liked that about it. Small and simple.

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(http://img524.imageshack.us/my.php?image=original1vy1.jpg)
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Firstly, I wanted to get rid of the spare floppy drive bay, It’s ugly and wouldn’t be used…
Started with some body filler (bondo to most of you guys ;P )
Took me a few goes to get it to the finish I was happy with. Not perfect but at the time I didn’t have a dremel.

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[IMG]http://img265.imageshack.us/img265/9646/bondo2wu5.th.jpg (http://img265.imageshack.us/my.php?image=bondo2wu5.jpg)
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http://img265.imageshack.us/img265/9133/bondo3yq0.th.jpg (http://img265.imageshack.us/my.php?image=bondo3yq0.jpg)*
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http://img404.imageshack.us/img404/7348/bondo5yz8.th.jpg (http://img404.imageshack.us/my.php?image=bondo5yz8.jpg)
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After I was happy with the finish covering the floppy drive bay, I then looked again at the front and thought there was still unneeded detail on it.
The grooves down either side and going into the fins had to go, again… off we go with the body filler…

Finally happy that it’s plain enough.

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http://img253.imageshack.us/img253/3447/bondo8nh1.th.jpg (http://img253.imageshack.us/my.php?image=bondo8nh1.jpg)
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I couldn’t decide on the colour for some time, after a while I decided to keep it black, but wanted a nice glossy finish to show off the plain look nicely, I ended up with a pearlescent paint, again, I though the extra sparkle would show off the plain look well.

[iCer]

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http://img253.imageshack.us/img253/6499/bondo9jj5.th.jpg (http://img253.imageshack.us/my.php?image=bondo9jj5.jpg)
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Here it is..
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http://img253.imageshack.us/img253/3351/front1uq9.th.jpg (http://img253.imageshack.us/my.php?image=front1uq9.jpg)
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http://img407.imageshack.us/img407/8056/front3do2.th.jpg (http://img407.imageshack.us/my.php?image=front3do2.jpg)
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After this I then started to work on the side panel (well I started in-between layers of paint – as you can see in the background of that picture I’d already got a rough shape cut) which is when I brought the dremel.
I started to plan this out on Photoshop to see what shape, and design to use. Again had to be simple, but I thought I could get away with more on the side as when it’s in use as a media center PC, it won’t be seen from the side much anyway.

Here’s the design in Photoshop:
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http://img522.imageshack.us/img522/2862/sidebasicel4.th.png (http://img522.imageshack.us/my.php?image=sidebasicel4.png)
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I then added the etching design I wanted, and then the frame of the inside of the case, Which at the time I forgot about, but had already started cutting the whole in the side panel – I’ll have to think of something to do with that at a later date – half way through the mod and still pondering.

To cut the hole in the side panel I started with my dremel, but soon gave up. This is an old case… No aluminum here – the case sides are all steel. With the standard cutting discs that came with my dremel (it’s actually Clarke, but everyone calls these things Dremel regardless) I managed to cut a two inch gash before the disc was too small to use.
So I put that down and got out the Jig saw. Progress was slow, and difficult, then the blade started to bend the edges of the metal and contort the side panel. So I had no choice, out with the angle grinder again. HAHA!
Bish bosh…. Rough shape….
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http://img522.imageshack.us/img522/3903/sideendcn7.th.png (http://img522.imageshack.us/my.php?image=sideendcn7.png)
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[iCer]

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http://img522.imageshack.us/img522/6793/rough1yt4.th.jpg (http://img522.imageshack.us/my.php?image=rough1yt4.jpg)
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Started with the Dremel again… hmmmm, nope still too much work for that to do. So I used the angle grinder again, rather difficult to do intricate work like those curves with such a big tool.

Finally got the shape, just needed the dremel to finnish the edges (I actually found the sanding pad’s were brilliant at this!
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http://img522.imageshack.us/img522/844/smooth1bq4.th.jpg (http://img522.imageshack.us/my.php?image=smooth1bq4.jpg)
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Once I was finally happy I started with the prepping, for the spray job. 3 hours of wet’n’dry later I was ready.
On with the spray…
I did about 5 coats, then had to rub it down again. Not all the way, but enough. When cutting the shape, I noted that jig saw had bent the edges a little. Well before preparing the surface to be painted, I tapped the medal after clamping with wood either side of the bent bits, and got it back into shape. Only the spray brought out the imperfections. After rubbing, then proceeding with another 6-7 coats of paint. It was to a standard I’m happy with. Not perfect, but good enough for me.

Forgot to take picture.. sorry.

I then needed to start on the acrylic panel – truth be told I started with in between coats of paint.
This proved more than interesting, and gave me a shock reminder of how dangerous power tools can be. I was cutting through the acrylic, with a newly fitted cutting disc – fitted as the previous ones I had been using were, when suddenly it exploded in my face. I felt a chunk hit me between the eyes, on the bridge of my nose. Just felt like a firm tap on my nose, like it someone tapped you with a pencil. I went to take a look in the mirror and could see a small bump with a tiny scratch on the top. I started then to think how much worse it could have been. An inch either side and it would have struck my in one of my eyes. To this day I have a small scab on my nose from this. And to this day I refuse to use those cutting discs, also started wearing goggles, which I now realize I should have been doing anyway!
Pics..
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http://img522.imageshack.us/img522/6128/dsc00821ww1.th.jpg (http://img522.imageshack.us/my.php?image=dsc00821ww1.jpg)
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[iCer]

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http://img522.imageshack.us/img522/1189/dsc00822hb2.th.jpg (http://img522.imageshack.us/my.php?image=dsc00822hb2.jpg)
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*http://img522.imageshack.us/img522/6104/dsc00823vy7.th.jpg (http://img522.imageshack.us/my.php?image=dsc00823vy7.jpg)
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http://img522.imageshack.us/img522/4629/dsc00824ce7.th.jpg (http://img522.imageshack.us/my.php?image=dsc00824ce7.jpg)
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On with the case mod after a few days off.

I decided to use a hacksaw to finish cutting the acrylic, then used the sanding pads to smooth it all out. I managed to slip a few times onto the surface on the acrylic, but luckily these are just out of sight once the piece is fitted. I will probably redo the acrylic at some point, but it will be okay for now.

I then wanted to make a start on the lighting. After reading a few posts on here, I decided to rig up some orange LED’s, I soldered 4 in series to put around the edge of the acrylic, which I will use to light up the design I’m going to etch into the window. I also wanted to light up the front grille, so I put together 6 LED’s on parallel, 5 for the grille and one to light the power button.
Forgot to take pics of doing 4 LED’s buth heres the 6..
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http://img522.imageshack.us/img522/5039/led1ci2.th.jpg (http://img522.imageshack.us/my.php?image=led1ci2.jpg)
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http://img522.imageshack.us/img522/7889/led3kc6.th.jpg (http://img522.imageshack.us/my.php?image=led3kc6.jpg)
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http://img522.imageshack.us/img522/4325/led4ve5.th.jpg (http://img522.imageshack.us/my.php?image=led4ve5.jpg)
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http://img522.imageshack.us/img522/4030/led5qr9.th.jpg (http://img522.imageshack.us/my.php?image=led5qr9.jpg)
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On testing these seem way too dull, and just give a spot light on the grille. Not what I wanted. Again after looking on here, I found the quick mod on the scanner light. And decided to try that as I had a broken scanner I’ve been meaning to chuck out. Did a bit of testing and got it lit up. Seems very bright, but hopefully when I manage to get hold of some thick orange acrylic, it should be okay. I’ll be wiring all the lights to a switch, and will only be putting the light on for short periods when showing people, as I am aware that the life of the scanner light may be quiet short using it like this.

[iCer]

Today I cut out the blow hole for the 120mm fan I intend to use. It’s a nice clear fan but with orange blades, which I think suits the theme very well!

Here’s some pics of me cutting out the hole…

Here I have lighly been round and made a grove around the line I marked out. Took the picture as I was changing the cutting disc anyway…. (don’t last long at all..)
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http://img522.imageshack.us/img522/9886/fan1ir1.th.jpg (http://img522.imageshack.us/my.php?image=fan1ir1.jpg)
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Thought I would show you all a picture of the fan I’m going to use there.
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http://img267.imageshack.us/img267/1324/fan2bz8.th.jpg (http://img267.imageshack.us/my.php?image=fan2bz8.jpg)
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After a couple more cutting disc’s I had cut a deep enough hole to leave the offcut in place but enough out to tap it away – I didn’t want it to drop while I was cutting incase it caught the disc and caused it to blow up in my face again (though I now where goggles when using it!)
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http://img267.imageshack.us/img267/6858/fan3bv7.th.jpg (http://img267.imageshack.us/my.php?image=fan3bv7.jpg)
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all the way around its like this, just hanging on by little threads… Nice!
I tapped the offcut twice very lightly with the screwdriver and away it fell.
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http://img402.imageshack.us/img402/905/fan4ar2.th.jpg (http://img402.imageshack.us/my.php?image=fan4ar2.jpg)
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Needed to change to a sanding pad, while taking the cutting disc off, it broke into pieces, I barely touched it!
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http://img402.imageshack.us/img402/148/fan6dv0.th.jpg (http://img402.imageshack.us/my.php?image=fan6dv0.jpg)
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sanding pad about to clean up the edges, Brilliant and durable attachment this!

[iCer]

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http://img48.imageshack.us/img48/3228/fan7mp2.th.jpg (http://img48.imageshack.us/my.php?image=fan7mp2.jpg)
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After the sanding…
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http://img505.imageshack.us/img505/1461/fan8zr6.th.jpg (http://img505.imageshack.us/my.php?image=fan8zr6.jpg)
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This is the stage I am at currently, and plan next to do the following.


Finnish spray job (lacquer)
Etch the acrylic
Find a way to incase the scanner light with orange acrylic
Wire the lights to a switch
Jazz up the HDD/FDD mountings in some way.
Spray the cd/dvd drives.
Get better looking internals, IE CPU heatsink/fan, RAM cover, GFX card cover.
Possible hide all the ugly internals with sprayed mesh (have seen this on some of the mods on here, looks very good – hope no one minds me using that idea!)

Would love to hear some comments.
Sorry I have not taken many pictures in progress, Firstly I hadn’t found this website when I started, and secondly I get too carried away while I’m working and forget to take pictures.

[Helix666]

Always wear your safety goggles. Your vision is a precious thing, and you can't afford to risk it.
</lecture>

Looking good so far. :D

[iCer]

Small update:

Have Lacquered the windows side of the case, and not the other, some reflection shots to show before and after.
With flash:
http://img408.imageshack.us/img408/5963/reflecktionbestflashyg1.th.jpg (http://img408.imageshack.us/my.php?image=reflecktionbestflashyg1.jpg)
Without flash
http://img408.imageshack.us/img408/4224/reflectionbestnp2.th.jpg (http://img408.imageshack.us/my.php?image=reflectionbestnp2.jpg)
With flash
http://img408.imageshack.us/img408/3791/reflectionflash1xh9.th.jpg (http://img408.imageshack.us/my.php?image=reflectionflash1xh9.jpg)

Just having to respray the font of the case, after I balls'ed it up, running out of lacquer and the spray can letting out big blobs that wouldn't absorb.

having been spraying the inside of the case too. I can't make my mind up if to lacquer the inside or not. Anyone think it's worth it?

http://img106.imageshack.us/img106/8481/sprayarea2iv5.th.jpg (http://img106.imageshack.us/my.php?image=sprayarea2iv5.jpg)

I'm still not sure what to do with the inside of the case. IE the frame and HDD bay.

Any ideas on this too?

[iCer]

No update for a while, I know.

Sorry, have been busy with work.

Getting close to finnishing this mod now, and it's triggered a re-name!

Black B[]x


I have to say that the pictures I have, in no way show the finnish on this.
If I'm honest, I had done very little comparied to some of the mods I have seen on this site.

Afriad again I got carried away while working so there are no "action" shots I know you are like.

here are the pictures I do have however:
Firstly, pictures of the frame, with only a basic coat of paint, wanted this part to absorb light rather than reflect, to give a better glow.

http://img404.imageshack.us/img404/2571/dsc00858hf2.th.jpg (http://img404.imageshack.us/my.php?image=dsc00858hf2.jpg)

http://img404.imageshack.us/img404/4662/dsc00861tu6.th.jpg (http://img404.imageshack.us/my.php?image=dsc00861tu6.jpg)

http://img404.imageshack.us/img404/8378/dsc00862nq6.th.jpg (http://img404.imageshack.us/my.php?image=dsc00862nq6.jpg)

Here are some pictures of the test fit. the front was still being worked on.
http://img404.imageshack.us/img404/471/dsc00865qd3.th.jpg (http://img404.imageshack.us/my.php?image=dsc00865qd3.jpg)

http://img404.imageshack.us/img404/48/dsc00866wp8.th.jpg (http://img404.imageshack.us/my.php?image=dsc00866wp8.jpg)

http://img404.imageshack.us/img404/8537/dsc00868lc6.th.jpg (http://img404.imageshack.us/my.php?image=dsc00868lc6.jpg)

http://img404.imageshack.us/img404/4413/dsc00871qs8.th.jpg (http://img404.imageshack.us/my.php?image=dsc00871qs8.jpg)

Some pictures with the gubbins:
http://img404.imageshack.us/img404/1315/dsc00880ko8.th.jpg (http://img404.imageshack.us/my.php?image=dsc00880ko8.jpg)

http://img404.imageshack.us/img404/1315/dsc00880ko8.th.jpg (http://img404.imageshack.us/my.php?image=dsc00880ko8.jpg)

And the front fan:
http://img404.imageshack.us/img404/7224/dsc00882qg3.th.jpg (http://img404.imageshack.us/my.php?image=dsc00882qg3.jpg)

Now I have the front fitted, it gives an Idea of why I decided to rename it...
http://img404.imageshack.us/img404/2638/dsc00885cg6.th.jpg (http://img404.imageshack.us/my.php?image=dsc00885cg6.jpg)

http://img404.imageshack.us/img404/245/dsc00886dd2.th.jpg (http://img404.imageshack.us/my.php?image=dsc00886dd2.jpg)

http://img404.imageshack.us/img404/1384/dsc00887jb5.th.jpg (http://img404.imageshack.us/my.php?image=dsc00887jb5.jpg)

http://img404.imageshack.us/img404/7215/dsc00889lk5.th.jpg (http://img404.imageshack.us/my.php?image=dsc00889lk5.jpg)

http://img404.imageshack.us/img404/1456/dsc00890rp7.th.jpg (http://img404.imageshack.us/my.php?image=dsc00890rp7.jpg)

http://img404.imageshack.us/img404/9632/dsc00891pz1.th.jpg (http://img404.imageshack.us/my.php?image=dsc00891pz1.jpg)

http://img404.imageshack.us/img404/2633/dsc00892gz2.th.jpg (http://img404.imageshack.us/my.php?image=dsc00892gz2.jpg)

http://img404.imageshack.us/img404/8766/dsc00894qu1.th.jpg (http://img404.imageshack.us/my.php?image=dsc00894qu1.jpg)

http://img404.imageshack.us/img404/6480/dsc00896nk0.th.jpg (http://img404.imageshack.us/my.php?image=dsc00896nk0.jpg)

http://img404.imageshack.us/img404/269/dsc00899qu6.th.jpg (http://img404.imageshack.us/my.php?image=dsc00899qu6.jpg)

Also went on to fit the CD drive - draw, covers. Now that they have dried.
http://img404.imageshack.us/img404/262/dsc00900qo3.th.jpg (http://img404.imageshack.us/my.php?image=dsc00900qo3.jpg)

http://img404.imageshack.us/img404/2623/dsc00901no9.th.jpg (http://img404.imageshack.us/my.php?image=dsc00901no9.jpg)

http://img404.imageshack.us/img404/7181/dsc00902sb2.th.jpg (http://img404.imageshack.us/my.php?image=dsc00902sb2.jpg)

http://img404.imageshack.us/img404/2586/dsc00904mj3.th.jpg (http://img404.imageshack.us/my.php?image=dsc00904mj3.jpg)



Things I have to work on next:

Fitting the power switch and reset button.

Lighting, I had been planning on using the white light from a scanner, covered with a orange film, but somthing fell onto the light snapping it in half. /me less than chuffed!

I have already wired some LED's up as per previous posts, so I will see what effect these bring.
If anyone has any Ideas for lighting, then please let me know, I would like to keep it Orange.

Fitting a mini USB hub, I think I will fit this internally, and possibly hookup the lighting to this, though I might just use a normal switch, as the machine could do with using the mini USB hub for normal general use.

Heres the mini USB hub:
http://img167.imageshack.us/img167/6379/dsc00906nw0.th.jpg (http://img167.imageshack.us/my.php?image=dsc00906nw0.jpg)

Make new design fitting the net case name for either etching inot window, or as I'm now thinking, onto the ugly internals (HDD, optical drive and power supply case, that is visible though the window - due to my poor placment!)

Polish more! I have been rather lazy and only gave I a quick polish, although in the flesh it looks fantastic, I just can't get the images to convey this. maybe more shine is required!

Possibly using mesh within the case, to conseal the motherboard, and gfx card.

Finnally to spruce up the internals by:
Getting a better looking cpu heatsink/fan, get another rounded IDE cable for optical drives. Heatsinks for memory.
Better looking headsink for Nothbridge.
cable wraps for the powe unit.


Hopefully I can start on the next parts of this after my holiday to Barcelona which is due in a coupleof days time. Wahey!!


Comments welcome, Good and bad!