Zebracorn - The Xbox in a PC Case Mod

[SchaibleTech]

A client called and asked if I could fix RROD's for Xbox 360's. I said yes. She said can you add LED's and paint it? Maybe a new, high performance fan so this doesn't happen again? I said yes again. She said 'I want to have something different." I said I was down for whatever idea she had. Well, she couldn't think of what she wanted, so I said 'What about putting it in a different case? It'll be bigger and painted and lit well, with extra fans for better cooling. She said 'that sounds awesome,' so here we are!

My name in Nicholas Schaible, and this is the Zebracorn.

She wanted a orange, green, and purple case, so that is what she is getting. I asked what kind of design she would want, and jokingly offered unicorns and rainbows. She loved the idea's of unicorns, but wanted the unicorn to be a Zebra and have stripes. I thought it was cool so I agreed.

Basically what i'm going to do is mount the motherboard with her hard drive inside the case. I bought three push-button switches to extend the Power, Eject, and Sync buttons to the front of the case. I'm also putting a fan in the front and back, and creating an air duct on the inside that passes right over the xbox motherboards heat sinks. So it will be intake, long tube, exhaust fan at the rear of the case. That way air is blowing in and out constantly.

Also soldered a 4pin Molex connection to the 12v on the xbox motherboard for 3 120mm fans and 2 12' Green cathodes that will go in the air duct.

And as a last touch, installing 4 acryllic green LED case feet for that extra bling.

Here some pictures to start of what I'm working with. I still have parts coming in the mail from MNPCtech and Frozen CPU and Newegg, so as soon as I get those in, i'll update the worklog.

Happy Modding!

Nicholas Schaible - SchaibleTechSolutions - ApolloCustoms.

FIRST. Lots of candy.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/384459_275561252504310_207487612645008_780779_1661 465728_n.jpg
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http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/374695_275561679170934_207487612645008_780787_4269 _n.jpg

[SchaibleTech]

Purchased all needed parts today! Now just to wait till they get shipped! The only thing left to do is get the sheet metal sized for the rear I/O panel, and the turbine wind tunnel for the xbox heatsinks.

x3 Scythe Slimstream 120mm
http://images10.newegg.com/NeweggImage/ProductImageCompressAll300/35-185-058-04.jpg

cheap fan controller, sunbeam 4 channel 20w.
http://images10.newegg.com/NeweggImage/ProductImageCompressAll300/11-995-011-02.jpg

x3 (WHAT I THOUGHT WERE FULL SWITCHES...turns out its just the cable...I need to find cheap push button switches. Suggestions?

http://www.frozencpu.com/images/products/main/ele-176.jpg

x2 120mm fan grill
http://www.frozencpu.com/images/products/main/fgc-02_2.jpg

16x screws for fans and case, also grommits courtesy of MNPCTECH.

http://www.mnpctech.com/Gold.thumb.screw.jpg
http://www.mnpctech.com/Black.pan.head.screw.jpg
http://www.mnpctech.com/GrommetWb1.jpg

TURBINE TUBE!!!
http://www.mnpctech.com/PortTubeWb.jpg

replacement xclamp parts for xbox 360 heatsinks.
http://ecx.images-amazon.com/images/I/41o3qjbUJRL._SL500_AA300_.jpg

and of course, plastikote primer and filler.
http://ecx.images-amazon.com/images/I/41fGpiva9LL._SL500_AA300_.jpg




I definitely spent 3 times what I planned on, but this is going to be fun as hell.

We begin modding next week! I'm going to solder the switch wire earlier in the week, so i'll post that update soon.

Later!

[SchaibleTech]

Started working!

First was soldering to the Sync, Power, and Eject buttons and testing switches to make sure everything working properly. Once all tested, Hot glued them down and giggity giggity!

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/382700_276597799067322_207487612645008_783285_1121 958731_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/402057_276597822400653_207487612645008_783286_5876 8510_n.jpg
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http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/387917_276597909067311_207487612645008_783288_1142 39144_n.jpg


And this is soldering to the 12v source on the motherboard so I can add my 3 molex connections.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/377432_276597952400640_207487612645008_783289_1069 336255_n.jpg

I suck at soldering, but you should have seen me 2 weeks ago...still works!

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/402463_276597992400636_207487612645008_783290_8509 76280_n.jpg

Splicing to the molex.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/394038_276598015733967_207487612645008_783291_1805 880870_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/396017_276598052400630_207487612645008_783292_1487 188166_n.jpg

Tested and everything works! All lights and switches are good to go :) Except for that RROD....

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/404285_276598069067295_207487612645008_783293_7539 76281_n.jpg


And as I was ending my night, i wasn't looking where I was grabbing and grabbed my soldering iron...

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403128_276598115733957_207487612645008_783294_5198 43709_n.jpg

prob one of the worst burns I've experienced. And without a left pointer finger and thumb I can't do much, so all work is on standby until my new parts come in.

thank you for looking!

[SchaibleTech]

I'll definitely pick up some flux then. I've seen it on the shelves in the soldering section, but never knew what it was. Thanks for the tips man I appreciate it.

And yeah they are both starting to blister...couldn't hold me back from working tho!

I finished cleaning up the switch wiring and the molex. So here are the leads for all those.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/383646_277211549005947_207487612645008_784782_1625 714124_n.jpg


http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/381648_277211609005941_207487612645008_784783_1928 360131_n.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/380806_277211759005926_207487612645008_784785_1292 340388_n.jpg

Also had to extend the DVD drive power cable to that I could have the drive in a 5.25 slot bay in the tower. This alone took me about and hour and a half to finish, and i plugged it in to test and all it did was buzz. I flipped out cause I thought I may have switched some of the wires around on accident. But then realized I grabbed a DVD drive with a dead motor...Curse me having boxes of xbox parts...

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/390216_277211775672591_207487612645008_784786_6661 1586_n.jpg
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http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/406390_277211835672585_207487612645008_784788_1345 469438_n.jpg



I'm not exactly sure what I want to do next. I could get a head start on painting the chassis...but on the other hand its 15 degrees out and I want to be out there as little as possible. Haven't succeeded on getting my dad to heat the garage yet...one day...

I think i'll wait for all the rest of the parts to come in to start working on this. Get everything organized and what not. Might be a few weeks cause Bill is in Vegas for a few more days.

Thanks for looking guys!

[SchaibleTech]

Hey guys! So it may not look like it took as long as it did, but I spent about 4+ hours working today on this bojangles. I made decisions and took action then changed my mind...so indecisive today hahah. But hopefully I ended up with what with look best.

Ok so first off, I was thinking that I was just toing to mount the motherboard right to the case chassis. And then after staring at these xbox parts for a while, I realized something. Ok so maybe Microsoft didn't cool their chips well enough, but they had a sturdy design for venting. I liked how that white plastic piece created a vent between the fans and heatsink. So I wanted to stick with that. Also, I though it would make the rear I/O shield in the rear. So, I decided I would mount the motherboard to the xbox tray, and then mount the tray to the case chasis.

**and just so you know, the motherboard I used in these photo's is a different motherboard than the one I'm using. With the constant in and out the motherboard was going to have to go, I didnt want to risk damaging the clients board, so I have been using my own for the time being.

So this is what the original xbox motherboard try looked like.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/407645_278136695580099_207487612645008_786908_1536 279872_n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/381722_278136725580096_207487612645008_786909_1006 138970_n.jpg

I cut the front I/0 panel off because there was no clearance inbetween the motherboard and the tray, so the wires that i soldered on could not fix. So I just cut that part off.

Cut chassis is on the left.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/395993_278136755580093_207487612645008_786910_5024 17121_n.jpg

I also wanted minimal resistance of airflow, so I cut out the xbox motherboard tray fan filter.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/376112_278136802246755_207487612645008_786911_1141 712827_n.jpg

I ended up cutting out that middle mesh piece cause I though it looked horrible.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/375976_278136852246750_207487612645008_786912_1274 588959_n.jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/386297_278136888913413_207487612645008_786913_2858 94325_n.jpg

here is what the front looked like with the front I/0 shield cut off.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc7/401695_278136922246743_207487612645008_786914_1823 329325_n.jpg

SO. This was the issue that I did not expect. The connection for the HDD is flimsy. I really wanted to avoid using the whole enclosure. So I did what I do best and took it apart.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/381889_278136948913407_207487612645008_786915_1888 873767_n.jpg

So I took out this metal cage that the hard drive mounts to, and I'm going to screw this to the bottom of the case. So when and if the hard drive ever has to come out, just take out 2 screws that hold the HDD to the metal cage, and it will slip right out. The metal cage will be secured to the chassis. This worked out because now there is no stress on the HDD connection, and switching it out will be way easier.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/392358_278136958913406_207487612645008_786916_1657 386885_n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/397371_278136985580070_207487612645008_786917_1800 165047_n.jpg

Random top shot.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/408350_278137018913400_207487612645008_786918_4394 43336_n.jpg

Alright so I got the motherboard in the cage, and now I'm testing out how i want to mount it into the case chassis. This is so I can figure out where I'm going to drill for my motherboard mounting screws and where I need to cut out of the back I/0 shield.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/395858_278137045580064_207487612645008_786919_3637 48380_n.jpg

First cut out.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/409216_278137075580061_207487612645008_786920_1569 279035_n.jpg

Just to get an idea of height, I put motherboard spacers in below the xbox motherboard tray to get an accurate reading.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/384474_278137125580056_207487612645008_786921_1111 071623_n.jpg

Now the green tape resembles what the custom sheet metal plate will cover in the back. So mostly everything will be covered except the xbox connections in the back. Going to the sheet metal place tomorrow to get pricing.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/392580_278137158913386_207487612645008_786922_2008 660206_n.jpg

Colored fan wires and fan stickers were making me angry, and so was all the dust on the fan blades. cleaned. Also cut out the middle part of the metal mesh.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/382756_278137195580049_207487612645008_786923_1347 707485_n.jpg

Officially mounted!!!!

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/402859_278137262246709_207487612645008_786924_9596 54799_n.jpg

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403970_278137345580034_207487612645008_786925_1947 977410_n.jpg

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This is me getting an idea for what I want the fan duct to look like.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/399993_278137825579986_207487612645008_786932_1855 692070_n.jpg
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/386488_278137885579980_207487612645008_786933_1659 252376_n.jpg

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I did another cardboard cuttout of something a little more simpler, but left the house and didn't take pictures. So tomorrow is going to be getting price quotes for these two sheet metal contraptions. That's it for now because I have a presentation for work I need to prepare. Till next time, thanks for looking!!!!

[SchaibleTech]

Looks like a great build. My only suggestion is don't use engine enamel for paint. Duplicolor will work much better if you're going with spray paint. Any suggestions or good resources for those rrod's? I have about 5 systems I can't seem to get working.

I've always had good luck with engine enamel paints. Any particular reason you don't like them?

Plus, already bought the paint...so I'm gonna use it hahah. But I do appreciate the advice!


Start here:
XBOX Error Codes (http://xbox-experts.com/errorcodes.php)

This is the only method that worked for me without reballing or reflowing:
Ultimate X-Clamp Fix (http://xbox-experts.com/tutorial/team-hybrids-ultimate-xclamp-fix-released/)

You can also review:
Fix Red Ring without Towels :) (http://www.instructables.com/id/Fix-the-Red-Ring-of-Deathwithout-towels/)

If you have the tools necessary, you can try:
Reballing XBOX 360 GPU (http://www.google.ca/url?sa=t&rct=j&q=reballing%20xbox%20360&source=web&cd=1&ved=0CDEQtwIwAA&url=http%3A%2F%2Fwww.youtube.com%2Fwatch%3Fv%3DOIw NSBtQKUw&ei=CHYqT9CPELO62gWGvZziDg&usg=AFQjCNFdqGOlLpgmNO9zeLr6WH5XjU8IhQ)

Looks like he beat me to it. It really depends what motherboard you have, because different xbox's have different model motherboards. Some, once you RROD you are kind of ****ed, but others you can do the xclamp/thermal past fix and be good. I'd say half the time you need to add more cooling fans because once they RROD once, they are much more susceptible and sensitive.

All the towel trick does is overheats your xbox and does a hardware reset. Its a temp fix and wouldn't recommend it.

I was able to get you guys one picture!!

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/407769_10150549018893089_709388088_9023445_1132594 981_n.jpg

[SchaibleTech]

Sent ya a pm, doooooooooooooood.

Alright guys here is an update! Not a huge one, but it's about 8 hours of work. Thanks again to Bill Owen of MNPCTECH for some great parts!

Luckily this cut didn't have to be perfect, because I didn't have a hole saw to cut out the front panel and the chassis. The plastic duct will be covering the jagged edges so it wasn't a huge deal.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/419315_289540401106395_207487612645008_811428_2124 804912_n.jpg

This is after cleaning it up a little bit.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/423251_289540461106389_207487612645008_811429_1265 228084_n.jpg

Here is the front panel with the fan duct from MNPCTECH.
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/431071_289540511106384_207487612645008_811430_1893 437948_n.jpg

here is the 3rd coat of the fibergalss filler. I POOPED ON MY FRONT PANEL.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/418810_289540577773044_207487612645008_811431_1951 639035_n.jpg
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/428961_289540664439702_207487612645008_811432_1610 658741_n.jpg

Here is the computer case panel, which is the left, top and right side all in one panel. Kind of inconvenient but whatever. Sanded and primed. On the right we have the chassis with the hole for the fan.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/417206_289540824439686_207487612645008_811434_1670 055613_n.jpg

5th coat of the fiberglass filler.
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/430817_289540901106345_207487612645008_811435_3757 12387_n.jpg

purple fan controller! (and orange knobs, which are not pictured.)

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/404486_289540961106339_207487612645008_811436_1215 782927_n.jpg

Looks mad red, but it's the lighting. it's orange.
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/427187_289541051106330_207487612645008_811438_7667 89816_n.jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/408089_289541167772985_207487612645008_811439_1055 15974_n.jpg

MNPCTECH Fan grommits! WOOOOOOOOOOOO!
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/420385_289541301106305_207487612645008_811441_1407 212033_n.jpg

Fan mounted and mnpctech tapered screws in!
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/406426_289541501106285_207487612645008_811443_1883 607483_n.jpg

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/409382_289541701106265_207487612645008_811445_1895 224179_n.jpg

This is the 2nd to last coast. I'm going to sand this down to the shape i want, prime it, and then will prob have to do a final coat to clean up some holes and gashes. That is going to take some time.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/417328_289541817772920_207487612645008_811446_1399 300397_n.jpg

Tried this fitting,and i'm going to have to sand down the fan duct a little more so this is flush. However I might just remove the black 120mm fan grill instead. Don't know yet. Can't decided if i like it with or without the fan grill.



http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/401539_289541974439571_207487612645008_811447_3065 56204_n.jpg

that's all for now! Since I'm painting in the garage, I'm giving the obejects im painting overnight drying periods because it's so cold. So tomorrow is final coat of orange on the case top/left/right panel, clear coat on the fan controller and knobs, sanding of the front panel and hopefully priming. We're moving on along!

Thanks for checkin this out! Nackers OUT!

[SchaibleTech]

Got the first coat of the fiberglass filler on today, and primed it too see where I needed to touch up. I got pretty damn close on the first coat, but it needs work. Still need to figure what I'm going to put in the 3.5' drive bay so sanction my 2 usb ports and power, reset, and sync buttons. Any help appreciated.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/395395_10150555418958089_709388088_9040265_7678940 21_n.jpg

[SchaibleTech]

Why don't you make a small panel to include all those, Nick? You use something like vandal switches...Also, which fibreglass did you get?

Lookin' good btw :up:

Yeah I'm just trying to think of the best way to do it. I don't have any of the 5.25 bay covers, so it's gonna have to be a custom job. I already have purchased the switches I'm using. I still need to buy the USB cable extenders. There are x3 5.25 bays open...one is going to be the dvd drive, one holds the fan controller, and the one in the middle is going to house the switches and usb ports. I was thinking that i could take a old cd drive and gut it, make a custom faceplate and drill holes for the switches and usb ports. that way the case fits snug into the drive bay and i can remove when necessary.

I gotta think about that one lol. The fiberglass is Dyna-Tron Dynaglass. Works pretty well, the only issue i'm having is smoothing out the line between the plastic and the fiberglass. But that's because I didn't sand it before applying like a loser.


It looks great, but...
It just keeps staring at me with a surprised face...

THAT'S HIS O FACE!


Thanks for looking guys!

[SchaibleTech]

Teaser photo! Here is the first coat of paint on the front bezel. Custom switch plate up top.

http://sphotos.xx.fbcdn.net/hphotos-ash4/419500_10150609269783089_709388088_9199344_1979699 793_n.jpg

[SchaibleTech]

And a mock put together.

http://sphotos.xx.fbcdn.net/hphotos-snc7/429888_10150609389683089_709388088_9199591_1221504 117_n.jpg

[SchaibleTech]

I'm assuming you're still working with RROD unit. How do you go about fixing the RROD for the Xbox? Or do you just send it to someone?

The first xbox rrod'ed motherboard I was working with is out of my hands now. I do not have any experience re soldering chips to motherboards, so I'm not going to attempt that right now. The new motherboard I'm using for this project has not yet RROD'd, it was just an extra xbox i had lying around. It's the Jasper motherboard, which is the least likely to RROD out of all the different version of the xbox motherboards. SO to keep it that way i'm installing 3 120mm fans, and did the xclamp and thermal paste replacement.

there are simple fixes and there are in depth fixes. A simple one would be to turn on your xbox but unplugging the fan to let it over heat. Then when it reboots it does a hardware reset and your fine.

A more indepth fix is removing the heatsinks and re applying a more high performance thermal paste, along with replacing the crappy xclamps with the nut and bolt replacement. ($5 on amazon.)

Then if you really want to get into it, desolder the chip. clean it up and resolder, and do the heatsink work I listed above.

[SchaibleTech]

Got the motherboard, fans, case feet and cathodes installed and the wires hidden to my liking. Only thing not hidden is the sata cable because it's not long enough. Oh well! Only things left to so is get the sheet metal for the back plate, and make cuts for the LED switches. Have to wait about 5 days for this paint to cure for the clear coat, and then I'm done!

Assembling took me about 3.5 hours yesterday because of non stop issues. I got it all put together and there was a short somewhere. Every time I touched the chassis it would turn on and sometimes the DVD tray would open. So I took it out and put it back in. Tested and everything worked. After a bit of playing around I noticed now the SYNC switch was not working properly. So I started moving wires around and the wire broke about 1/4 inch from the solder point. So I had to take the motherboard out again and resolder the sync button wires to the board. Put it back in and it was still shorting out. But then I pulled all the wires out of hiding and re did them. Then I realized that I mounted the hard drive to the motherboard cage...but didn't plug it in .....:(

So I took the mobo/cage out one last time, plugged it in, got everything together and looking pretty, and it's good to go now. So happy that I am nearing the completion of this project. So happy.

Here are 2 cell phone pics of what it looks like.

http://i452.photobucket.com/albums/qq244/buhbarose/2012-03-01_19-44-29_904.jpg?t=1330691975

http://i452.photobucket.com/albums/qq244/buhbarose/2012-03-01_19-44-15_751.jpg?t=1330691974

[SchaibleTech]

And done!

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/424378_309588515768250_207487612645008_857297_3482 62624_n.jpg