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Step 3Putting it all together
Ok, well now that you have all the parts to this puzzle ; let's put it all together.
#1. Start with your Dewalt Tool Box.
Prepare your box for anarchy.
Cut all inserts (dividers) inside of the box out. I've done this with a Utility Knife, and a grinder. Also measure and cut the areas out of your box where your boards ports are going to need to be exposed as well as the power supply area. Importantly on the PSU note - make sure you leave a bit of plastic to screw the PSU to the side of the tool box. Next lightly sand the bottom flat ; because you will have ridges in the plastic dividers still exposed from cutting.
Your Dewalt tool box is going from holding tools, to holding expensive hardware - so clean everything thoroughly after you do this job of preparing your box for the motherboard and hardware.
#2. Decide where it's going to go.
Mapping out where components are going to go is part of the entire mystery in this project. Every component is different, so you'll need to find what works for you. Generally the smaller the better ; and going mini ATX on everything can really make this project go quickly. You won't run into too many problems.
I , on the other hand - choose an AMD board for this project which was small but a full sized ATX motherboard. This made things a super tight fit between the motherboard and the PSU ; so modification to the Power Supply unit housing was required.
#3. Installing the Hardware
{ 3.1 } Mount your motherboard using the stand offs with flat bottoms first. I recommend removing the double sided backings on them if they are there ; and 2-part epoxy, supergluing / gorilla gluing / etc.. to the chassis. It has to be hard core stuff, because you won't want to fiddle with ones that have worked their way loose later. Remember to drill holes over your CPU heat sink & fan assembly .
I like to construct rubber 'shocks' for the bottom of the board, and sides touching the case for extra chaos protection.
{ 3.2 } Mount any PCI cards you need ; half sized ones are A-OK ; but you'll run into problems with full sized ones. Remember to drill a hole for that wifi antenna. Mounting the cards without the brackets is also an art. I just used zip ties in the end.
{ 3.3 } Mount your mini ATX power supply using ALOT of two part epoxy to make it stay (forever!) in the case and not move. This is crucial. Everything has to be stationary. * see video below *
{ 3.4 } Mount the hard disk as shown in the video below. It comes sideways off the handle area ; and is built with an air gap in mind to keep things cool. It also suspends the hard drive ; to avoid shock.
{ 3.5 } Hopefully, you also have a fan speed controller and temp display & sensor to hook up as well. I highly recommend this ; it will prevent you from getting your new box too hot.
But hey, not enough ugly green paper is something I can relate to. If built without one, just make sure you put plenty of holes over the CPU's fan and heat sink ; and a fan over the hard disk area.
{ 3.6} Hook up your on/off switch & LEDs where ever you want ; I installed mine at the base of the box so I could kick it under a table to start the PC up.
{ 3.7} Install (temporarily) an IDE or USB external CD-ROM drive to transfer your favorite OS flavor.
#1. Start with your Dewalt Tool Box.
Prepare your box for anarchy.
Cut all inserts (dividers) inside of the box out. I've done this with a Utility Knife, and a grinder. Also measure and cut the areas out of your box where your boards ports are going to need to be exposed as well as the power supply area. Importantly on the PSU note - make sure you leave a bit of plastic to screw the PSU to the side of the tool box. Next lightly sand the bottom flat ; because you will have ridges in the plastic dividers still exposed from cutting.
Your Dewalt tool box is going from holding tools, to holding expensive hardware - so clean everything thoroughly after you do this job of preparing your box for the motherboard and hardware.
#2. Decide where it's going to go.
Mapping out where components are going to go is part of the entire mystery in this project. Every component is different, so you'll need to find what works for you. Generally the smaller the better ; and going mini ATX on everything can really make this project go quickly. You won't run into too many problems.
I , on the other hand - choose an AMD board for this project which was small but a full sized ATX motherboard. This made things a super tight fit between the motherboard and the PSU ; so modification to the Power Supply unit housing was required.
#3. Installing the Hardware
{ 3.1 } Mount your motherboard using the stand offs with flat bottoms first. I recommend removing the double sided backings on them if they are there ; and 2-part epoxy, supergluing / gorilla gluing / etc.. to the chassis. It has to be hard core stuff, because you won't want to fiddle with ones that have worked their way loose later. Remember to drill holes over your CPU heat sink & fan assembly .
I like to construct rubber 'shocks' for the bottom of the board, and sides touching the case for extra chaos protection.
{ 3.2 } Mount any PCI cards you need ; half sized ones are A-OK ; but you'll run into problems with full sized ones. Remember to drill a hole for that wifi antenna. Mounting the cards without the brackets is also an art. I just used zip ties in the end.
{ 3.3 } Mount your mini ATX power supply using ALOT of two part epoxy to make it stay (forever!) in the case and not move. This is crucial. Everything has to be stationary. * see video below *
{ 3.4 } Mount the hard disk as shown in the video below. It comes sideways off the handle area ; and is built with an air gap in mind to keep things cool. It also suspends the hard drive ; to avoid shock.
{ 3.5 } Hopefully, you also have a fan speed controller and temp display & sensor to hook up as well. I highly recommend this ; it will prevent you from getting your new box too hot.
But hey, not enough ugly green paper is something I can relate to. If built without one, just make sure you put plenty of holes over the CPU's fan and heat sink ; and a fan over the hard disk area.
{ 3.6} Hook up your on/off switch & LEDs where ever you want ; I installed mine at the base of the box so I could kick it under a table to start the PC up.
{ 3.7} Install (temporarily) an IDE or USB external CD-ROM drive to transfer your favorite OS flavor.
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Sep 1, 2009. 3:53 AMfrikkie
says:
This is so awesome!Maybe with oil rings,silicone and rubber you can even make it like waterproof.I once saw the old army radios;they are in heavy iron casing.If one of those radios ever fell off an army jeep,the radio was still in working condition.On its insides,the pc boards are mounted on metal plates that again have springs that help to absorb shocks from falling.
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9
Jul 31, 2009. 10:26 AM
kelseymh
says:
kelseymh
says:
This is an excellent project. It's too bad you didn't take pictures along the way while you were building it, but thanks much for putting in the interior detail shots here. In Step 3, I would encourage you to split this out into three separate I'bles steps. I suspect it'll make things a bit easier to follow.
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6
Aug 1, 2009. 9:11 AMcapth00k (author)
says:
I'll take it apart to break it down better and provide more pics for you guys
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