HTPC - Woody

[laserkitty]

I wanted to replace the second HTPC in the bedroom (HTPC2 in sig) and connect to the Sony 40S3000 (http://www.sonystyle.com/webapp/wcs/stores/servlet/ProductDisplay?catalogId=10551&storeId=10151&productId=8198552921665067954&langId=-1) I just got for $549 (http://www.fatwallet.com/forums/messageview.php?catid=18&%20threadid=768400&messid=12012485&start=2656), but I didn't want a regular case-type PC case. I had toyed with the idea of building the components into one of the dresser drawers, but the wife was having none of that.

Well, she's out of town for a week (hence the new TV and my selling the "old" plasma (http://cgi.ebay.com/Panasonic-TH-42PX75U-42-TV-HDMI-Optical-cables_W0QQitemZ300203620186QQihZ020QQcategoryZ110 73QQssPageNameZWDVWQQrdZ1QQcmdZViewItem) that never even made it out of the box :) ), so around my honey-do list, I'm building a wood case that can sit on top of the dresser and look fashionable and decent.

Components as of now: Mobo: EVGA 650i Ultra (http://www.newegg.com/Product/Product.aspx?Item=N82E16813188017)
CPU: Dual-Core 2140 (http://www.newegg.com/Product/Product.aspx?Item=N82E16819116037) (soon to be replaced by a Q6600)
RAM: Crucial 4GB (2x 2x1GB) 240-Pin DDR2 SDRAM DDR2 667 (http://www.newegg.com/Product/Product.aspx?Item=N82E16820146526)
Video card: PNY 6600GT (http://www.pny.com/products/verto/performance/6600gtpcie.asp) (to be replaced by Diamond HD2600XT (http://www.newegg.com/Product/Product.aspx?Item=N82E16814103038))
Drives: WD Raptor WD360GD 36GB (http://wdc.custhelp.com/cgi-bin/wdc.cfg/php/enduser/std_adp.php?p_faqid=872&p_created=1039465570), Seagate Barracuda 7200.10 ST3500630AS 500GB (http://www.newegg.com/Product/Product.aspx?Item=N82E16822148136), Lite-On LH-181P DVD+/-/RW (http://www.liteonit.com/global/index.php?option=com_content&task=view&id=179&Itemid=67)
PSU: Antec Earthwatts 430w (http://www.newegg.com/Product/Product.aspx?Item=N82E16817371006) (since it's going to be running 24/7, might as well be enviro-friendly)
PVR Cards: DViCo Fusion5Lite (http://www.fusionhdtv.co.kr/eng/Products/RTLite.aspx), Hauppauge PVR-250 (http://www.hauppauge.com/pages/products/data_pvr250.html) (to be replaced with PVR-500 (http://www.hauppauge.com/pages/products/data_pvr500mce.html))
Other: Soundgraph/imon UltraBay (http://www.pcalchemy.com/product_info.php/pName/soundgraph-imon-ultrabay-internal-vfdcontrol-panelir-receiver-black)This is what I've got done so far: Flickr set (http://www.flickr.com/gp/7325563@N03/2A9n39).

As you can see in the pictures, I cut up a hard drive bay and cut up an old PC case-panel to connect the HD bay to the DVD drive. I was going to leave the HD bay alone and use it is-as since it orginally had a fan built into the bay, but it was too tall for my plans, so it got modified.

You can see that I am also mounting the UltraBay directly to the side of the DVD drive, which does two things for me:
ensures that the UltraBay and the DVD drive are aligned
makes it a lot easier to cut/shape the front panel of the box
I'm going to cut the fan-holes in the sides as soon as the second coat of lacquer dries, but before I sand the panels again. Then I'll apply a third caot and do one final sanding, or just rub the panels down with a brown paper bag to smooth them.

When I cut the fan holes is when I'll make the cutouts for the DVD & UltraBay, and when I'll drill the location for the power switch.

I haven't decided whether I'm going to hinge the top and have the front rest on velcro, or use quick-release pins or what. That'll probably be the last thing I decide.

This is my first major mod (I did do the dual-PSU mod a few years ago).
Your thougts and comments would be appreciated.

[silkshadow]

Very, very cool! Wood work is beyond my ken but it looks very good so far. This may be a dumb question, but is there any fire risk for for running a box in wood?

[laserkitty]

Risk of fire? Man, I hope not!

There really should not be, and the overall heat should not be any more than any other case, especially with the blow-through fans.

And thank you!

[laserkitty]

I painted the HD-DVD mount pieces using matte black (high temp paint left over from re-finishing my grill) and installed the actual DVD drive, the Raptor and 500GB hard drives, and mounted the UltraBay.
http://farm3.static.flickr.com/2076/2306806742_505a655691.jpg
http://farm4.static.flickr.com/3280/2306005939_96a10d0f20.jpg
http://farm4.static.flickr.com/3204/2306807032_013892ba7f_m.jpg

I made the cut-outs for the drives in the front panel, then I lacquered the front, top, and side sheets again, this time using high-gloss (I'd been using semi-gloss Satin for some reason?!) They looked really good this morning.

Pics tonight.

[silkshadow]

Looking forward to your final result. I would like to replace two of my HTPCs with a wood case if it works. Will look a lot better on dressers in the bedrooms.

[splat]

http://www.flickr.com/photos/7325563@N03/2305238296/in/set-72157604024305772/ hehe, i have those same slippers but Maryland, of course.

[laserkitty]

Looking forward to your final result. I would like to replace two of my HTPCs with a wood case if it works. Will look a lot better on dressers in the bedrooms.
Yeah, when I first thought about just using a drawer, I was jaw-dropped by how simple that would have been to set up, and how clean that would have been, as far as having components in the open (none, except maybe an IR receiver.)
T'was not to be but that gave me the excuse to get the UltraBay, which is a fun gadget.

[laserkitty]

Panels, now with 250% more shine!
http://farm3.static.flickr.com/2287/2308073097_2db75e2cdf.jpg
http://farm3.static.flickr.com/2383/2308072937_370145ed91.jpg
(also in this shot: my 1969 AMC AMX, under cover, and my trusty Avenger.)
http://farm4.static.flickr.com/3006/2308878416_39a87cb334.jpg

On the suggestion of someone at work, I think I'm going to put the power and reset buttons on the back of the case. While I think it will look pretty good the way I've got the button set to mount, there really is no reason to have the front face marred by anything poking through. Especially since the clear ring around the button will be lit blue by LED...or not if I don't connect the "power LED" lead. This picture shows the spacer I cut so that when the button is mounted, it will be exactly flush with the outside of the case. I had to sand the wood at an angle to get the button assembly to lay flat on the spacer.
http://farm4.static.flickr.com/3097/2305237672_4d5d3fe40b_m.jpghttp://farm3.static.flickr.com/2326/2304440693_17c6a6ece0_m.jpg

[=ACID RAIN=]

This should be interesting :)

[laserkitty]

No pressure. They don't fit, I start over...:(

http://farm3.static.flickr.com/2226/2309240388_38e0ac5ee4.jpg

It fits! :beer:
Looking at it now...I kinda think I might go ahead and put the power and reset switches on the front. Kinda looks bare on the right, don'tcha think?

I made some cuts in the motherbaord tray to allow the power lines to run underneath:
http://farm4.static.flickr.com/3255/2308436481_9bd6ded301_m.jpg
http://farm3.static.flickr.com/2011/2308436319_0a850bddc9.jpg

Now I need to mark the side panels for the fans:
http://farm4.static.flickr.com/3127/2308435617_4130eafa36.jpg
http://farm3.static.flickr.com/2340/2309240544_23968189d9.jpg

I still have almost no idea have to actually mount/connect the mobo tray to the base board. I was thinking maybe using some of the other form-factor holes to screw into the board below...maybe using the BTX or M-ATX mounting holes, or something.
Ideas?

[Wayward_Son]

"I was thinking maybe using some of the other form-factor holes to screw into the board below...maybe using the BTX or M-ATX mounting holes, or something."

That's a very good idea.

Use that which already exists which fits your ultimate end results while making the fewest possible modifications.

That's my modding philosophy, and I'm sticking to it.

[Albaholic]

Nice, subscribed... Any plans to make the drive bezels wooden? I realize it would be very difficult to do with the Ultrabay thing

[laserkitty]

You know when you get that feeling like things are going too well? I decided to try the fit-test again, this time putting the lid/top on.

Nuts.
http://farm4.static.flickr.com/3196/2308679215_95e3ff31dd.jpg
http://farm3.static.flickr.com/2055/2309484630_c2b93cc2d0.jpg

The cards are about 1/8" too tall.
http://farm3.static.flickr.com/2018/2309484476_934c0f94e7.jpg

Possible solution: cut 1/8" deep channels where the mobo tray sits so it sit's that much lower into the base/bottom board.
Downside: the 24-pin cable is tight snaking under the tray as it is. I suppose if I take it out of the net sleeving, it can spread out more flat, and since it's is below the tray anyway, there is no real need to have it sleeved.

Other solution: put the front and side panels on top of the bottom board, instead of around it, effectively raising the sides by 3/4".
Downside: I would need to shim the drive rig to raise that, too. I would need to cover the unsightly plywood that would become visible.

[Jolly-Swagman]

Here is a solution to your problem
1/ remove motherboard tray
2/ use either the brass motherboard raisers just drill holes slight smaller and they will self tap into wood
3/ you can get motherboard mounting raisers that are plastic and are the stick on type

#2/ is what I did for my Firewall box and #3/ have used these in an older case as the old mounting hole didnt line up and couldnt redrill as they were to close

Just some thoughts

Jolly Swagman

[laserkitty]

I thought about just tapping holes and mounting the mobo directly to the base, but I like the use of the back-panel for aligning the cards and using the motherboard peripherals plate...though...hmmm.

I wonder if I could drill out the rivets and screw that back panel directly to the base board?
http://farm4.static.flickr.com/3161/2309464217_3ccd3122d4.jpg

[Neuromancer]

You could do that.. but have to add channels for the bottom of the pci cards

Might want to rethink your optical drive mounting mechanism, wood is extremely resonant, and DVD drives spin up and vibrate the entire case. some type of rubber mounting and a little extra space around the front panel (filled with some plastic edging or something) would do wonders at removing some of the vibration. (I went to far as to but a rubber pad under my hdd bay too).

Looks nice otherwise cant wait to see it finished. :)


Oh just thought of something else.

add 1/4" risers under he top of the lid. Have all case fans blowing in and let them exahust out hte gap i nthe top.

If you are using quiet components it should not be much louder then it will enclosed.

[laserkitty]

That last idea sounds promising, especially coupled with adding rubber spaces to the drive-rig. I was going to use a thin rubber diaphragm under the HD mounting, but your suggestion to put it around the bezel is a good one, too, and raising the overall height of the lid would accommodate that shift in dimensions!

Thank you to everyone for your input and suggestions, I truly do appreciate the other points of views and ideas.

[laserkitty]

I thought about the riser for the lid, but cutting the channels was quicker.

http://farm3.static.flickr.com/2012/2310799651_1661918417.jpghttp://farm4.static.flickr.com/3059/2310799935_0653ce7b86.jpg
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http://farm3.static.flickr.com/2179/2311608190_1fe7d153bf.jpghttp://farm4.static.flickr.com/3292/2310798655_caa3ce0381.jpg

Dremel + Radial-arm saw FTW!

So, I need to: affix the mobo tray to the base
pre-drill the sides to the base
tap the base and insert ... insert thingamadoogles to screw the sides into
cut some cubes to place in the corners, and drill & tap the sides and front
cut the back piece and varish, sand, varnish, sand, varnish it
figure out whether to put the power button on the side, the front, or the even the back.
http://farm3.static.flickr.com/2245/2310798821_967d67385c_m.jpg
finish the wood floor in the foyer before the wife and daughter get home and I can no longer leave my tools laying around
finish watching Deadwood
drink a Fat Tire

[Jolly-Swagman]

Thats looking really great the slots for the tray was a good idea too

[leftkidney]

looks cool, but you should of used some veneered plywood and got some for the edges also the grain would be finner and not look like something from the 70's no offense mate

[DUSNOETOS]

I ve been thinking about building my own case for a while now..... I build loud speakers as a hobby job. So building a computer case would not be all that hard... what is hard is finding the time to do so. (being back in collage with a child on the way)

[laserkitty]

looks cool, but you should of used some veneered plywood and got some for the edges also the grain would be finner and not look like something from the 70's no offense mateYeah, I've thought about that once or twice, too, but I had this stuff on hand. I'd looked in to picking up some maple and I think that would have done the trick. No offense taken, and I do have aplan to spruce it up a little...somehow. :)I ve been thinking about building my own case for a while now..... I build loud speakers as a hobby job.My original plan was to use a dead subwoofer that I'd emptied, but it was too small for al the components.

[dsb1829]

So, I need to: drink a Fat Tire

Now you're talking :beer:

and one for the road :beer:

[laserkitty]

...the grain would be finner and not look like something from the 70's...Daaaaaaaaammit! You suck. You're right, though.

I went to Lowe's to get some rubber foam weatherseal (http://www.lowes.com/lowes/lkn?action=productDetail&productId=96244-1410-R534H&lpage=none) to line the DVD-front panel area with and some rubber shelf liner (http://www.lowes.com/lowes/lkn?action=productDetail&productId=41157-133-00-26395)for sound deadening, then I picked up some small (1" x 3/4")hinges (http://www.natman.com/prodinfo_itemdetail.asp?cat=23&sub=69&prod=219&catalog=469&item=1790), and some corner moulding (http://www.lowes.com/lowes/lkn?action=productDetail&productId=862-1487-206&lpage=none) that I am going to put on the corners and around the perimeter of the lid.

So I'm standing there and I keep thinking, "You know, if you're going to do this, you might as well do it right. It wasn't that hard to cut those pieces, you could have another set done in no time, and make them slightly taller and move the drvies-bay over just a touch to make it easier to affix the corner..."

So I picked up a sheet of birch and as soon as I'm done with the 1/4 round moulding for the floor, I'm going to start re-cutting all the panels. I should be able to get them done tonight, which means I could stain them tonight, too, and lacquer tomorrow before I leave for work.


And I was sooooo close to being done...:bang head

[laserkitty]

Broke a cutting disk:
http://farm4.static.flickr.com/3230/2314070702_eaeb5ce7d3.jpg
Dang thing shot pieces right up under my goggles, hence the title of this post. I am okay, though. Rinsed the eye out and finished cutting the last, like, 3% of the front panel using a box-cuttter.

I made the new panels 1/2" taller and I offset the drives-bay by 1/2" to the center, to allow for the corner moulding I'm going to put on later.
http://farm4.static.flickr.com/3079/2314070338_1836c0118a.jpg

[DUSNOETOS]

NOT TO DIS YOUR METHODS. But why were you using a metal cutting disk to cut wood. Your lucky you did not catch fire.

any nice jigsaw and a steady hand will produce wonderful cuts (just use a fine tooth blade.)

[laserkitty]

No jig-saw, plenty of dremel disks.
(and my Sawzall is overkill)
((and it did smoke a ton))

[laserkitty]

I should have ordered from these guys last week: low-profile buttons (http://www.happ.com/pushbuttons/ilumn3.htm) & regular buttons (http://www.happ.com/pushbuttons/pushbuttons.htm). :drool:

[laserkitty]

I finished the floor yesterday and tonight I couldn't sleep, so I find myself about 95% complete on the box.

Yesterday I pre-drilled the front and side panels, then did a fit-test using the foam-rubber weatherstripping:
http://farm4.static.flickr.com/3139/2317491427_fedc9aea92.jpghttp://farm3.static.flickr.com/2213/2317491517_af2971d248.jpg
http://farm3.static.flickr.com/2330/2317491593_3b861d826a.jpghttp://farm3.static.flickr.com/2057/2317491917_9f2769c356.jpg

[laserkitty]

Today, I came home from work a little before 2:00 due a slight change in weather.
Witness before (60+ degrees) and after (sub-30 degrees):
http://farm3.static.flickr.com/2383/2308072937_370145ed91.jpghttp://farm4.static.flickr.com/3172/2318299652_797a92afe8.jpg

I installed all the hardware and screwed down the mobo, but only on one spot since the back wood panel will hold the rear of the mobo-tray down and in place.

Anyway, I made a template for the real panel and I think it came out pretty darn good:
http://farm4.static.flickr.com/3182/2317492257_a92efb839b.jpghttp://farm3.static.flickr.com/2057/2318299932_b0482e0124.jpg

I started the thing up and all is well so far:
http://farm4.static.flickr.com/3263/2317493167_19c4b5719c.jpg

Finally, around 1:00 this morning, since I was still up, I went ahead and cut and stained the moulding because there's nothing better than power tools when you're tired, but can't sleep, right?)
http://farm3.static.flickr.com/2414/2318300760_8fea55869b.jpghttp://farm4.static.flickr.com/3245/2317493325_ac7ef42632.jpg
(I see that last shot and think, "Two-by-two, hands of blue..." Who's with me?)

[laserkitty]

After a busy morning...
http://farm4.static.flickr.com/3129/2318964409_94acc02feb.jpg
(keep in mind that there was nothing on the ground until about noon yesterday, and this shot is from ~9 this morning.)

I'm gluing on the moulding this afternoon.

I was going to use double-sided carpet tape, but, again, if I'm going to do it, I might as well do it right the first time.
http://farm4.static.flickr.com/3047/2319965398_cbf0fa88f6.jpg

The weather is delaying ther return of my wife and daughter, as they are driving back from Florida, so, now I nurse a Leinenkugel Sunset Wheat and figure out what else to do around the house while the moulding is clamped.

[laserkitty]

I decided to put the power and set buttons in back, above the PSU. I think it's cleaner than having them in the front.
http://farm3.static.flickr.com/2282/2321190743_408f90605c.jpg

This is the finished case:
http://farm3.static.flickr.com/2249/2321191437_e722833272.jpg
http://farm3.static.flickr.com/2072/2322008666_90b7456a5b.jpg

I used some small brass "hobby" hinges for the lid. Each rated at 2#, so 4 should be overkill.
http://farm4.static.flickr.com/3069/2322008862_cae8c706ee.jpg

And I took a variation on Neur0mancer's advice ("add 1/4" risers under he top of the lid. Have all case fans blowing in and let them exhaust out the gap in the top.") and used weather stripping to make a kind of vent around the top:
http://farm4.static.flickr.com/3022/2322009228_8822e5be34.jpg


I want to thank everyone that popped in and left a comment or a suggestion, especially leftkidney, Jolly-Swagman, and Neur0mancer, whos comments specifically lead to design changes or additions.

Now, with my wife having just cleared Cincinatti, I figure I completed this project with a whole 2 hours to spare! She had fun in Florida and I had fun at home = win-win!

[SuperDave1685]

Very Nice! I likey :D Although if you do decide to get a Q6600 and a 2600XT, I'd maybe look into a 500W+ PSU. Something like the Corsair HX520. Good wok bro!