Project: Citrus G5

Well the epoxy seems to be holding up quite well so i dont think i'll be adding more to it.

I got myself a cheap 6pc file set (4 files & 2 handles) for like $15. I spent about 4hrs total cleaning up the window edges. Note to self; cut closer to the line next time.

Here you can see the huge chunks i had to clear from the corners.

Here it is all done:

And all together.

I dont think i'll be keeping the original plexi air baffle. I have a sheet of orange plexi i'll be using for that.

Also, my Imon UltraBay is currently on its way and should arrive before friday(fingers crossed)

Lookin' good, dude. Nice file work, your corners look excellent.
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Chrysler sebring (sedan) specifications

Yes, Corners definitely look good. This is a very cool project, I love the Citrus idea.. kind of like "apples and oranges" haha.. :)

ha ha, apples and oranges. good one :P

i agree, nice lookin window :)

That window cutout is spot on bro! Good Job. Pluz+Rep

I've been so busy lately... Anyway, i got the power supply mounted last week. Here's how it all went down.

I couldnt find much in the way of stencils so i put a sheet of paper over the PSU and incerted the screws through it. I then used the piece of paper to mark out my mounting holes. Well this wasnt very accurate and i had to drag the drill bit to get everything lined up correctly. It isnt a big issue as the screws i'll be using cover up the uneven holes except for one which has a tiny bit of the hole showing. Then i used an old psu as a stencil for the blow hole and filled in the slots with a jiffy marker. I wasnt sure how i was going to go about this at first so i drilled a couple starter holes (the 4 you see around the blowhole) After doing so i realized that the hole will be too big. I grabed a 80mm fan duct and eye'd it out on the aluminum. The duct fit inbetween test holes so i traced it out and began drilling. I drilled the circumfrence of the hole then used my dremmel to finish it off.

I then filed the excess material. This piece of the case is about half the thickness of the side panel and was much quicker. About 10 minutes later i had this.

After taking the picture i could see that the hole wasnt quite perfect so i touched it up a tad. Its easy to file corners but circles seem to be next to impossible to get perfect. (sry, no pics)

Well now i had to prep the PSU. The power cord socket, on/off switch, and voltage selector were protruding and needed to be removed. I couldnt remove the voltage slector so i screwed it to the ground terminal inside. I ran a new power cord to a filed down plug i made to fit the existing rear of the case. To do so i had to knotch out a small section of the cover and install a gromet for saftey. Here it is with a mock up of the power cord sticking out from the side.

I just realized that i didnt take any pictures of it all finished so i'll do so now and add them onto this post.

The hole is not as good as i wanted and my brother enticed me to touch it up and make the hole a little bigger if i have to. I'll post pics of that when i get around to it.

Here is another little mini mod that i havent finished. Its the fan bracket that goes between the cd drive and the HDD. There was a small squirrel cage fan and an 80mm fan mounted here but the squirrel fan cant be used so im hacking of its section from the bracket. I'm not sure yet if im going to use this but im thinking about it.

Also, since i've got the ultra bay now and it has blue illumination, im going to use blue led fans insted of hunting for orange ones. I think the orange and blue will look together and opens my choices for fans.

More Progress!

I got the front cut out for the ultra bay. Its a really nice fit.

Here was my initial markings, i made sure the sides were perfect and marked where i want the top to sit. The bottom line is a ruff estimate and makes the hole a little smaller than the ultra bay.

Here is the ruff cut with the dremel.

I didnt get any pics after filing the hole to neer perfection but here's one with the ultra bay in the hole. Its a bit funny looking because i had to hold the unit in place to take the picture, i also fliped the pic the right way around. The little bit of black along the top is my pen line and not a hole :) There is no play what so ever.

While i had the components removed, i touched up the PSU hole. It still isnt "round" but i smoothed out the funny bits and it looks better. I also touched up the I/O hole i hade and squared it off.

Mounted the Ultra Bay!! Major milestone here!!

I was so stumped and confused about how i was going to mount this after i had cut the hole for it. My frist thought was to fasion a block that would take up the space from its mounting bracket to the devider plate and glue it in place. I couldnt find anything to use as a block so i decided to use some screws and a bunch of nuts. I just fliped the bracket upside down and randomly put 4 holes in the bracket. I tested it out.

Turns out the screws i had were too short so i went and got some longer ones. This is a crappy pic but you can see how i marked for the holes. I used the short screws and just drew around them :) Turns out this worked pretty damn good.

And here it is all done and installed! I just need to tweek the bracket a bit in the top left corner. Its slightly out by about 1/16, otherwise its a flush fit.

I also finished the fan bracket also, i am fairly certin that im going to use it.

The list of things-to-do is getting smaller by the day. It shouldnt be too long before i start on body work and paint.

Lovin' it. The Ultra Bay is SWEET. :)
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FORD ORION PICTURE

Love the Ultra Bay!

I'd get some cheap "red" (red-orange) LED fans - close enough, really, and blue's altogether too common, if you ask me.

Which... you didn't.