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TonyAKAMrClean
03-10-2010, 03:54 AM
Hello all :) Glad to finally be posting here.

Alright, so as it all starts: During my senior year in high school (2003) I was given an old (circa 1997) Gateway2000 computer, complete with a 200mhz Pentium 1 (With MMX, might I add) and a whopping 64mb of PC-100 ram! I basically used it as a music box for years, but actually used it as a stand-in when I had problems with my main box, believe it or not!

http://img690.imageshack.us/img690/8681/image0069.jpg (http://img690.imageshack.us/i/image0069.jpg/)

When I built my main system, I threw my hardware into this thing just as a placeholder. I cut the fan hole in the front for added airflow. While I was painting my main case, I really wished I was actually modding this case instead. Here we are 6 years later, and I'm finally doing just that!!! This is My Inspiration box. You'll all have to bare with my camera, as it's just my cell phone and also bare with my newbescence, as this is my first real complete case mod :) My objective though is simple: Bring out this case's potential, the way that I think it should've been built in the first place.

Originally, I was going to mod the bare metal and leave off all the plastic, covering the frame myself with Plexi but then decided it was easier to mod the plastic instead of moving drive bays etc. Not to mention it looks righteous in the end.

First things first: Airflow & PSU mounting.

http://img718.imageshack.us/img718/8417/imag0343.jpg (http://img718.imageshack.us/i/imag0343.jpg/)

The case originally had an matx power supply but had room for a full atx power supply. It also only had 1 80mm exhaust fan but again, had room for 2 :) After paint I'll cover the Mr. Penut shape's edges with U-Channel molding, same for the PSU hole which will also get 1/2" washers.

There were NO front fans! just a small vent. Again, enough room for 2 80mm fans (in front of the hd bays, which are vertical in this case - AWESOME!) :

http://img218.imageshack.us/img218/1707/imag0292.jpg (http://img218.imageshack.us/i/imag0292.jpg/)

As you can see, I still need to cut the 80mm fan holes out, right now they're just drilled to a honeycomb goodness but that's pretty messy under the fans. I'll make the 80's a penut shape just like the ones in the rear. I also need to cut the 120mm fan hole.

Part of the reason this case is my Project Inspiration is because of MNPCTech's Turbine Blowhole Video: http://www.mnpctech.com/mal.html

"Why?" Many of you will ask - Because after watching this video I decided it was about time I did something with this case! Not to mention - That "Obnoxious Orange" and blue lighting frikken turned me on! :) That said, when the case is painted, it'll also be using blue lighting and a Chevy Orange engine enamel. There will also be a lot of chrome lining on this case - More on that later.

Now on to the fun part - BONDO!

http://img30.imageshack.us/img30/5987/imag0295g.jpg (http://img30.imageshack.us/i/imag0295g.jpg/)

Thats how the front panel was GOING to be at first, with a vent riveted in place on the piece you see in the center, chrome lining on both sides... You'd be surprised thoough how hard it is to find brackets to make it happen. I started cutting my own out of pipe letting and then decided to bondo instead:

http://img534.imageshack.us/img534/6982/imag0300n.jpg (http://img534.imageshack.us/i/imag0300n.jpg/)

http://img684.imageshack.us/img684/1400/imag0312z.jpg (http://img684.imageshack.us/i/imag0312z.jpg/)

Here you can see how much the profile changed... It's a bit more aggressive. I may still raise it out a bit but this is pretty much how it will stay:

http://img442.imageshack.us/img442/9873/imag0308.jpg (http://img442.imageshack.us/i/imag0308.jpg/)

This small change allows room for a 120x38mm fan as well as the 2 80mms which will all be sitting below a vent.

I've got to say: If you're planning on using Bondo inside - DONT! Especially if you live in an apartment like me :) It was freezing cold outside though and my Bondo wasn't setting yet I was freezing my knuckles off applying it. My roomate thinks I'm crazy because my apt smelled like a chem lab for a few days! So anyways, this is my first time using Bondo... Not bad for now but I still need to finish and sand. Thats at a hault though because of a lack in decision of power buttons.

--THIS IS WHERE YOU ALL COME IN!!!--

http://img696.imageshack.us/img696/8114/imag0336c.jpg (http://img696.imageshack.us/i/imag0336c.jpg/)
http://img62.imageshack.us/img62/611/imag0338r.jpg (http://img62.imageshack.us/i/imag0338r.jpg/)
http://img121.imageshack.us/img121/9051/imag0340.jpg (http://img121.imageshack.us/i/imag0340.jpg/)


I purchased some buttons from Radio Shack, didn't like em... I chopped some buttons off another old case, like them, but not sure if I want to use them... REALLY like Vandal Switches - but they're expensive... and I'm not sure if i'll like that area of this case, the way it's shaped today, slanting back all plain. Let me know your thoughts on this one guys!!! That third picture is what the buttons would look like if they were bondo'd into the bezel vertically. If I do this, I'll have 3 or 4 holes in the panel the buttons are in:
1 or 2 to mount a piece of plexi to it and 1 for Power LED to come through and light up the plexi, possibly one for HDD unless I mount the HD LED elsewhere.

What I think would be cool is - bezel | Plexi | Button Panel | plexi attached - The front plexi being used for HDLED to shine through, the inside plexi being used for Power LED. That would be tricky though, as the inside plexi that would glow would need to be removable to allow bondo/painting/sanding.


Modder's Must: Teach yourself to solder :)

I tought myself how to solder in order to salvage some BRIGHT blue LEDs out of a non-functional LED light tube. There's 12 of 'em in there, why let em go to waste? I've got to say though, if you've never soldered before, it's probably MUCH easier to solder an LED that has full-length leads on it :) After pulling the LEDs out, the leads were about 1/16th of an inch which made things tough! Here's the finished result though, for power/HD indicators:

http://img94.imageshack.us/img94/5167/imag0330p.jpg (http://img94.imageshack.us/i/imag0330p.jpg/)

Not bad for free! :) While considering what to do in terms of power LED if I were to bondo in those old buttons, I thought I'd use a pen tube as a placeholder... While test-fitting, I noticed something REALLY cool! Check it out:

http://img251.imageshack.us/img251/6420/imag0326.jpg (http://img251.imageshack.us/i/imag0326.jpg/)

I liked how this looked so much that I plan to incorporate lighting in this manner in the front bezel between the top 3.5" and 2nd 5 1/4" drive bays. I think I'd also like to do something like this across the front of the vent with an etched piece of plexi in the center. Agh... I forgot about the vent, didn't I... Here it is (test fit):

http://img638.imageshack.us/img638/9504/imag0319.jpg (http://img638.imageshack.us/i/imag0319.jpg/)

The chrome lining is actually Chrome door edge U-channel that you'd find at an auto parts store. I cut it at a 45 degree angle for this fit however I may end up rounding out those interior edges a bit more so that I can use a single piece. I kind of like the 45 degree though on this.

http://img707.imageshack.us/img707/4295/imag0322.jpg (http://img707.imageshack.us/i/imag0322.jpg/)

The vent material is actually pet-resistant screen that you'd use on a screen door often scraped up by dogs/cats. It's nice and durable, easily replacable, cheap, good air flow, very flexible, and did I mention - cheap? I've got plenty and plan to use it more often in the future. The only bad thing about it is the flexibility keeps you from using it on fans. Aside from that, I'm loving this stuff!

Alright, so I'll be updating this worklog as I progress but that may be a long road ahead of me. I'm sure you all can relate! I am pretty diligent about this project though, as I'm anxious to get to the point where others start seeing my vision on it. Please feel free to comment and make suggestions. The power button dilema is a real hold-up for me right now. Suggestions?

Trace
03-10-2010, 12:35 PM
Looks good! Very nice start!

and let me be the first to welcome you to TBCS

TonyAKAMrClean
03-11-2010, 03:11 AM
Looks good! Very nice start!

and let me be the first to welcome you to TBCS

Thanks for the warm welcome!!! I'm not sure anybody even cares or is interested in what I'm doing with this case, but I know that a worklog is sort of necessary for me in terms of keeping things going. Not to mention I love this site, and everything it stands for.

So, the tough decision of power buttons has been solved... I decided to go for the gusto, as tough as it is, or will be... I decided to bondo on the buttons that I hacked off the other case.

Button prep:

http://img43.imageshack.us/img43/6034/imag0345.jpg (http://img43.imageshack.us/i/imag0345.jpg/)
http://img101.imageshack.us/img101/9577/imag0353.jpg (http://img101.imageshack.us/i/imag0353.jpg/)

I covered the outer edges to keep bondo out and used a cut up pen shell as a placeholder for LED placement, screw placement, and one in the reset button hole, as it will get quite a bit of bondo around it. The plexi you see is where the glowing plexi will be that will act as the PowerLED. When all is said and done, it should look like a glowing strip, contoured with the rest of the case... Starting to see my vision yet?

One problem that I ran into though as you'll see in the following pics is the plexi glass that I put in as a placeholder. Believe it or not, the tiny bit of bondo I put on to hold the piece in place to enable me to remove the tape actually HELD the plexiglass... I ended up just bondoing over it because that's basically all I can do at this point until it's cured and I can dremel it out. Tough luck on that! That's going to add some extra time to this for sure, and I'll have to do it right or else my paint job is sure to get screwed up, if I leave any of it in there.

First round of button bondo:

http://img192.imageshack.us/img192/3624/imag0357.jpg (http://img192.imageshack.us/i/imag0357.jpg/)
http://img198.imageshack.us/img198/9615/imag0359f.jpg (http://img198.imageshack.us/i/imag0359f.jpg/)
http://img684.imageshack.us/img684/9708/imag0361y.jpg (http://img684.imageshack.us/i/imag0361y.jpg/)

To anyone who hasn't used bondo before, this will look terrible... But, for something like this, It's tough to get it put on in a pretty fashion for the first round of bondo. No worries, after tons of sanding and another application and sanding again, it will be nice and smooth like the rest of the bondo'd surfaces :)

Alright, so that's it for tonight... My bondo's dry so I'm going to do a bit of sanding, then bed time... Hopefully the plan I had for this thing is starting to materialize for others as well. I would've done the whole google sketchup thing but I'm just too lazy and too busy :)

Please feel free to comment/make suggestions.

Trace
03-11-2010, 03:30 AM
Coming along nicely. Don't feel bad, with this nice of work, you will have lots of people following shortly!