I had a BT Vision Box (1st Gen) collecting dust and thought it must be usable for something, it doesn't seem hackable in anyway BT had it locked down pretty well, but it has many standard reusable parts. I also have an O2 joggler (an early runner in tablet computing that is quite limited in its 'out of the box' form but is very hackable and able to run various distros. Along with a few spares kicking around I built this media player.
This is my first 'Instructable', so please forgive any noob errors.
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Step 1: The BT Vision Box
First get your BT Vision Box (I've seen them for under a tenner on ebay) and open it up. In the centre you will see a 160GB hard drive and on the left the power supply. You will also need the fan and the phono sockets on the main board.
Carefully disassemble everything. Recycle everything that you will not use.
Step 2: Other Parts
You will also need the following;-
A CD ROM drive with and audio cable connector.
An audio cable (no longer used these days but connects CD ROM's to the MOBO).
A molex Y splitter cable
A multi USB port/adaptor
2 x IDE to USB cables
A USB extension cable
All either in the back of a cupboard somewhere or very cheap second hand / ebay etc.
Step 3: The Case.
Now this is where I'm sure people can be much more creative than me and create an amazing case out of something unusual. I'm a wood man generally, so wood is what I used until I come across something better.
Photos are self explanatory. Just make the required holes for CD Rom drive, power cable, phono sockets, USB lead and fan.
Step 4: Audio Cable and Phono Sockets.
With your audio cable obviously one end will connect to your CD Rom drive the other needs to connect to the phono sockets that you have detached from the main board of the BT Vision box (see photos). Generally the outside cables are audio left and right with the two middle ones being ground wires.
Step 5: Fitting the Parts
Now begin to add the parts to your case. Using wood makes it very easy to screw in retaining or mounting bits of wood for the various components.
Step 6: Fitting the Parts 2
With the drive in place I put in some wood supports for the powers supply and screwed it in place. You will also notice that I had to extend the fan wire to reach. I intend to add a switch for the fan as it is quite noisy, I usually leave it detached as cooling doesn't seem necessary with this roomy case.
I mounted the hard drive on the underside of the lid of the case then connected both drives to the USB hub (you could obviously add other devices here e.g you could run a bootable OS from a memory stick).
Step 7: Connect It Up
Plug in the leads and close it up ready to install your OS & test.
Step 8: Install Your OS
For the OS I have used a bootable USB version of Linux. So on a PC I installed the OS to the hard drive in the case (as though it was a flash drive) then extended the OS partition using GParted (otherwise it will be limited to 4GB).
Hope that makes sense - helpful links below.
I used the Joli OS as it is still finger friendly on the joggler screen. I connected a mouse to the USB hub for convenience.
I cannot get Joli OS to recognize the CD Rom drive so have connected that to my speakers from the phono sockets.
You will need two audio inputs on your speakers, one for the CD Drive and one for the Joggler.
Obviously you will need to transfer your media files to your hard drive, I found the easiest way was shared folders over the network.
Boot up and enjoy.