Update: The reason I have not had to use a resistor to stop the PSU auto powering off is that (it think...) the led in the switch I used draws enough current to prevent the PSU shutting down.

So I needed a bench top power supply and decided to make another PC power supply conversion tutorial. I used my CNC though, so this is less of a tutorial and more of a build log.

I uploaded this here in the hope that anyone making one for themselves can perhaps take inspiration for there own build.

Step 1: Design

I designed the parts in Illustrator and saved them in SVG fromat so my CAM program can process them for my CNC machine (see video for machining)

Step 2: You Will Need

You will need:

1. a PSU (ATX size) from a computer that has about 300w of power (depending on what you are going to use it for) 2. binding posts (here is a UK link for where to get THEM)

3. A latching switch of some kind (I used one with an led ring around it built in)

4. a piece of low density foam (fan filter)

5. some wood glue

6. 10mm plywood for the frame... PLANS

7. 3 M3 screws/bolts with washers.

8. a CNC machine...you probably won't have this...sorry!

Step 3: Cutting and Gluing

Watch my video to see my machine cutting out the pieces, you could do the rabbit joints by hand but it would be tricky in plywood!

Glue it all up and clamp it in place.

Step 4: Sand Down, Varnish Front Panel and Paint the Rest of the Box

Sand down with some fine sand paper to remove any burs and get edges perfectly smooth if not already.

I used varnish on the front panel for aesthetics as I like the wooden front with a matt black back to the box.

Step 5: Add Binding Posts

These binding posts were nice and cheap and do the job nicely. they have a bolt that pokes throught the front pannel and a little tab like washer which you can solder to on the other side. Secured in place with a nut.

Step 6: Assemble and Wiring

I then put the power supply in the housing and bolted it into place. I then soldered everything up. {I used two wires per voltage to increase the current output at each voltage if i needed to power a heavy duty motor or something. The switch I used had a built in led ring around the button which can be connected up to 5v and will illuminate when the power supply is turned on.

On the subject of the switch, i messed up the hole for it as you can see in the pictures, so I machined a little wooden washer which I stained a dark oak colour for contrast.