Page 1 of 5 123 ... LastLast
Results 1 to 10 of 49

Thread: WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

  1. #1

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    5.25" Embedded Motherboard PC (Commissioned Build) – Day 1
    Note, click on images for higher res. versions.

    Some time back I responded to a forum (OCAU) member looking for a case to be custom built. I replied Well, being my first commissioned custom case job as I wasn't sure what to expect… and I definitely didn't expect a 5.25" Embedded Motherboard PC! In fact, I hadn't even heard of it. Well, not to be put off and following my ideology that nothing is too big or too small, I took on the job.

    Brief
    Custom 'functional' case as small as possible, based on the Commell LS-570 5.25" Miniboard (Ref.: http://www.commell.com.tw/Product/SBC/LS-570.HTM)
    No frills: no lights, no extreme cooling, no details, no paint jobs, no windows, no, just a plain functional smallllll form factor case.

    Acrylic or aluminium
    2x Low-profile PCI on riser card
    1x 92mm fan
    1x 2.5" HDD
    Power button ('sales' potential! )
    Small front panel LCD (Ahhh, frill!)

    Hmmph. Not what I was hoping for. Nevertheless, a very intriguing project. Doing a little research I realised that there is a whole new world of computing out there that follows this 5.25" form factor. Intriguing indeed.

    Purpose/Details:

    [quote:1fb15d4229=Customer/Owner in another forum]I am the happy owner, and very impressed with the case work so far :-)

    The LS-570 was ordered from commell in taiwan it was $300 usd, i am going to put linux on the cf card and use the 2.5" disk for media, the pci slots will contain a dvb-t card and an adsl2+ card if i can find one, sangoma delayed their version :-(

    It has two sata and one ide so you it can support 4 disks you would just have to build a case that had space for the disks :-)

    it will have a 1.66G t2300 dual-core processor, 2GB ram and a ABGN minipci wifi card

    the plan is to use it 24x7 as a ipfilter firewall with snort inline, mythtv backend, torrent client, asterisk voip, cups printing and a music server, distro will probably be gentoo with a hypervisor and lcdproc will be feeding the lcd.

    Drawing board

    No drawing board for this one, instead I arranged, several weeks later :embarrassed: for the client to come over and spend the day together to get this project off the ground and discern directly from him what his expectations were.

    Construction - Day 1

    Well, not used to collaborating on a project, or having anyone else in my little worksop for that matter, I was distracted and didn't take any pics… except this one:


    Two weeks later (today), I quickly snapped off a few more before I progressed with the build and offer something visual for the start of this worklog.
    By the end of that day, we got as far as working out the overall dimensions and catering for the various extremities, locating the 2.5" drive, 92mm fan and front panel LCD and power button. The base plate was cut and motherboard standoffs tapped and fitted. The HDD mounting was also devised and partially constructed (U-channel on the left of the photos).
    525embed/images/CIMG7170.25a.jpg">
    Dreadfully dark pics, sorry. I can't be bother correcting them so you'll just have to squint and look closely.
    The other day I just had to drag myself away from the supplier product details I had been working and started to map out the rear panel cutout… this was going to be a little tricky.

    The extent of the front panel fabrication completed on that first day.


    Well, this is start. Hopefully I'll get a chance to progress this (maybe even complete it?) by the end of this weekend.

    Cheers guys and have a good weekend!
    GAM

  2. #2

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    5.25" Embedded Motherboard PC (Commissioned Build) – Day 2
    Note, click on images for higher res. versions.

    Well I did manage to get something done yesterday, but not as much as I'd hoped.

    Rear Panel Cutout
    Okay, well a short day of cutting and filing…initial rough cuts using the bench mounted jigsaw.

    First test fit. Note, at first I thought I had made a mistake by cutting through from the bottom instead of within a hole i.e., removing the bottom edge, but then I recalled that this rear panel will be fixed to the top and sides which will be removable to gain access to the interior and the PCI and Riser Card. It is actually an awkward arrangement with the PCI cards. You'll notice that the PCI brackets are, unconventially, external. Due to the arrangement of the rear ports, some recessed some protruding, there are few convenient options.

    Lots of fine tuning with a file to get the panel to sit all the way down. Note that the bottom edges (left and right) should touch the ground.

    It took an hour or two just to get this to sit right. I'm still not sure exactly how I am going to fill the gaps, but I do have some ideas that I hope to explore next. An additional alu section will be cut and permanently mounted to cover the exposed area beneath the ports and possibly cut to fit between the ports, but I think I will probably use some thin plastic instead for this purpose… easier to cut out the fine details required. Note, I should point out that the board doesn't come with a I/O shield like ATX motherboards!


    Front Panel LCD Cutout

    Leaving the rear panel on the back burner for the time being, I finished of the filing and cleaning up of the LCD cutout. This is just a mock up i.e., the LCD is not attached.


    I was also deliberating over the front panel fixings. Originally I had planned on all rivet and screw fixings, but I think the front panel should probably be glued in place to keep a nice clean fascia. The top panel will be fixed to the sides and the sides screwed to the base to complete the enclosure. I'll probably go with double-sided tape to fix the LCD to the front panel.

    Sorry for the crappy photos, I must have changed something on my camera. I'll look into it for the next round of photos.

    Cheers
    GAM

  3. #3

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    5.25" Embedded Motherboard PC (Commissioned Build) – Day 3
    Note, click on images for higher res. versions.

    Another couple of hours spent in the workshop this afternoon and I've got something that resembles an enclosure…

    Removable Top Section

    Having cut the two side panels and top panel to size on the table saw (after wasting at least two pieces of alu due to stupid errors) I laid them out ready for alignment, marking and fixing.


    This time around I decided to try my 'adhesive-tape-prefixed-method' before drilling and riveting rather than messing around with awkward clamping arrangements for drilling. Note LARGE roll of 3M Double-Sided Adhesive tape (soon to be available in store… albeit in smaller rolls ). I applied the tape to the pieces of angle and channel that will be used to fix the side and top panels to each other.

    You wouldn’t know it, but I made my first mistake in this area… I had affixed both joining pieces to the outer edge of the panel where they should have been recessed by the thickness of the side panels. Doh! Some gentle lifting with a screw driver and some serious sideways pulling on the joining pieces and I back a few steps. Note, this tape has some serious adhesion!

    Right then, having applied fresh strips of double-sided tape, I was ready to try again. Note the tape appearance after removing the red backing tape.

    Two joining pieces affixed to the side panels ready for application and then mated for a little 'vice' adhering help.


    Rear panel with joining angle affixed in place.

    Quick tip… I lightly affix the tape to the mating piece, align the edges, smooth out any ripples, air, eta and then cut to length insitu.

    Tape applied to the adjoining faces ready…. And then… an enclosure in the making.
    ed/images/CIMG7193.25a.jpg">
    Another quick tip… finger nails are often insufficient to relieve the backing tape so a little 'sharp edged' help is required… anyone here read fingernails? :roll:
    Note, although the technique is correct, in fact I failed here and lifted the adhesive… it is a harder with one hand.

    Now we start to really see the makings of an enclosure—inside and rear.


    Preview…
    With the removable top/side panels affixed in place with double-sided 'tape of the gods', sans rivets, we have a surprisingly solid, stable structure. I inserted it over the rear PCI brackets, gently persuaded it in place and we have a fine preview of what will be. Note that the LCD has been very loosely affixed in place behind the front panel using two tiny pieces double-sided tape.



    Now, before you get carried away and think the outer panels are almost done, note that there are no vertical joints and the left-hand side of the top panel needs to be trimmed to size.


    Next things to do include:
    - top panel 92mm fan inlet
    - hard drive fixing points (top panel)
    - side panel located vent (HDD side)
    - trim top panel to correct dimensions
    - vertical joining pieces
    - drill and rivet and/or tap threads for all joining panels
    - properly align and affix LCD
    - cut out bottom panel Compact Flash card access
    - cut and fix bottom rear panel to cover exposed area and consider further gap coverage…
    - file, sand and deburr all faces and edges
    - affix litte rubber feet (elevating the whole enclosure a couple of millimetres)
    - and anything else that I've forgotten or overlooked.

    Thanks for following everyone!

    Cheers
    GAM

  4. #4

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    5.25" Embedded Motherboard PC (Commissioned Build) – Day 4
    Note, click on images for higher res. versions.

    Finally a couple of hours spent in the workshop this afternoon until I had to give in to an oncoming illness… I seem to be coming down with something

    Removable Top Section continued…
    Two more corner pieces have been cut and affixed in place using double-sided tape.

    Then after a big round of measuring, checking, marking, punching and drilling… we have more permanently fastened panels together. Note though that these rivets will be replaced with countersunk versions before a finish is applied.

    Now to tackle the oversized top (3mm or so too wide). I used the table saw to get it down close without touching the side panel.

    And then finished off with a bastard file and then smoothing file. I've put a slight chamfer on it so as not to touch gouge into the side panel. I intend to put a 45 degree bevel on all these edges later, so the chamfer won't be present when it is all done and dusted. (no flash, flash )


    Top Panel Intake Fan

    With the top section now a little studier I decided to tackle the top panel intake fan… the only fan. After marking it our and punching, I realized I had my first mistake of the day… I punched the mounting holes 5mm too short on each corner. Never mind, I corrected this, drilled all the pilot holes and then realized another slight oversight… I hadn't taken into account the piece of joining angle beneath. No real dramas, I just have to cut out a section of it later so that the fan can sit flush to the underside of the top panel.

    92mm hole saw to the party. This bugger must be getting blunt because it took way longer than it should have.

    Voila! Top panel fan hole. I've also inserted the front panel for artistic impression It is not mounted yet, but will be mounted to the bottom panel/motherboard tray.
    _0403.25a.jpg">

    I had to succumb to 'miserableness' at this point with this cold/flu thing getting the better of me. I'm sure this is why I made silly mistakes today… at least that's what I'm sticking too

    Next things to do include:
    - hard drive fixing points (top panel)
    - side panel located vent (HDD side)
    - tap threads for all joining panels
    - properly align and affix LCD
    - cut out bottom panel Compact Flash card access
    - cut and fix bottom rear panel to cover exposed area and consider further gap coverage…
    - file, sand and de-burr all faces and edges
    - affix little rubber feet (elevating the whole enclosure a couple of millimeters)
    - and anything else that I've forgotten or overlooked.


    Cheers
    GAM

  5. #5

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    The Project is coming along GREAT!

    MOD ON!

  6. #6

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    Cheers Thrasher!

    I hope to have it finished by the end of the weekend ready for powder coating next week.

    Cheers
    GAM

  7. #7

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    Wow! Powder coating! What color? And by whom?

  8. #8

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    Haha, well the client would have liked 'Flame Red' but to keep cost acceptable i.e., avoid min. cost of AU$100, he's quite happy to go black Hopefully the local powder coater will have a run of charcoal or satin black, being quite common. This way the case can be put through with another run and then we need only pay for the case pieces... about AU$20.

    This will be the first time I've used powder coating, so it will be an interesting first experience.

    Cheers
    GAM

  9. #9
    The Main Man Dewayne's Avatar
    Join Date
    Mar 2006
    Location
    Arizona
    Posts
    3,646

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    Looking good there GAM. Building from scratch takes a lot of planning especially for a tiny case. Usually thats half the fun :-)

  10. #10
    Master Modder
    Join Date
    Nov 2006
    Posts
    2,059

    WORKLOG: 5.25 Embedded Motherboard PC-COMPLETED 1 Dec

    wow mad ive never seen one of them before....you a lucky person indeed.....anyway nice it is coming along very well! cant wait to see this powder coat.....

Page 1 of 5 123 ... LastLast

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Similar Threads

  1. Replies: 0
    Last Post: 02-11-2014, 09:39 AM
  2. Tt Kb/Mouse Mod Stealth Worklog [Completed]
    By attix84 in forum Tt eSPORTS / Thermaltake KB/Mouse Mod Work Logs
    Replies: 52
    Last Post: 03-08-2012, 09:43 PM
  3. Meshie (Completed)
    By Tazz in forum Modding Work logs
    Replies: 126
    Last Post: 08-23-2007, 11:11 AM
  4. firefox embedded video problem!
    By sinan in forum Talk Freely
    Replies: 1
    Last Post: 04-21-2007, 05:07 PM
  5. Bring Embedded Technology to Intel-Themed Motorcycle
    By THRASHER2 in forum Talk Freely
    Replies: 4
    Last Post: 04-06-2007, 10:19 AM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •