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80/20 SSF - Linux Workshop PC

C

crowat

Limp Gawd
Joined
Dec 15, 2009
Messages
231
Hi Everyone,
I’ve been a long time lurker on these boards and I’ve wanted to get into modding/design for quite a while.

I have finally reached a point where I can dedicate some time/resources to this hobby and I wanted to share what I am currently working on. Also, I have been quite interested in building a SFF PC. It’s not going to be super tiny but it will be the smallest PC I have ever owned.

Here is an idea what I am building. The goal is to create a SFF Linux PC for my workshop. This is just the inner workings there will be an outer shell.


Please be gentle. I just recently picked up Google Sketchup and I am very much still learning.

The current components are going to be (pretty much what I have laying around atm):
Zotax Mini ITX w/ION GPU
HDD (currently my spare Vertex 3 SSD)
Picopsu 90 & AC-DC 12V 7.5A 90W

Materials:
Aluminum Frame (80/20)
Aluminum Shell
Plexiglass Mobo Tray
Plexiglass HDD Tray
 
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The goal was to get the frame built tonight. Maybe start working on the slide out tray. I apologize for the crappy pictures my nice camera decided to die a couple of weeks ago and I am still looking for a replacement.
Material for the frame, 1inch aluminum tubing.


3 Way Corner Connectors – I know it feels like I am cheating a bit by using these but it’s my first ever build and I am sure I will have many challenges even with just using these items.


I decided to use the band saw to cut the aluminum tubing. As I am a one man shop I didn’t take any pics of the cutting process. Also, most importantly! Make sure you guys use the appropriate eye / hand safety equipment while cutting metal as there was aluminum shavings flying all over the place.


The base tubing cut. Note the bad measurements. Man am I glad that I double checked my measurement before making the first cut. I did have a hard time making the cuts as I don’t think I was patient enough. Just something I will have to work on, but the best way to learn is to keep trying.



The bottom of the frame together.


It took a couple hits with a hammer to get the connectors to fit. The manufacturer of the tubing / connectors recommended a rubber hammer (conveniently sold on his site for $29.95). I just used a piece of scrap wood and my regular hammer. Again my goal is to get more pics up of the actual assembly going forward. I am going to borrow a camera with a stand so that I can get that up.

Poor craftsmanship - You can see the gaps due to the bad cutting technique. I measured out the frame and I think that I am good for now as all of the sides match up. This is something to consider for future projects.


 
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The next item on the to-do list was to cut the tubing for the top supports. This is where I hit the my first snag as I ran out of tubing… I was about 180mm short… 

Oh well I will have to order some more and work on something else till the new piece comes in. This is where I left things off.


Also, a couple of teasers of things to come.



 
Day Two.

Hi Everyone!
Its been a long week. I have a pretty decent size update for you guys.

First thing I tried to do is cut the plexiglass sheets. I used my jigsaw and a fine tooth blade for the cuts.


And the other one.


Now to pull out the mobo for some measurements. This is pretty much the whole thing (w/out the HDD). You can also see some other things that I currently plan to use.

I forgot to take some pics of me doing the measurements. I did take a pic of the mess made by the cutting.


You can see my ghetto guide fence.


Ok, its time to pull out the coolest tool I have. The line heater.



Testing the heat.


The bending.


The result.


Now the real thing. (A couple of photos of the heating came out really blurry and would only give you a headache).


Another angle.

And the other side. Note that as the acrylic is getting heated it curves up. When it is ready for bending it will curve down. (see pic below).

Up.


Down and ready for bending.


Cooling in the Jig.


Test Fit.


GAHHHHHHHHHHHHHHHHHHHHHHHHH. I totally screwed up that one… Just plain sucks. Somehow I was 10mm off on the middle part. Thank you ADHD.
This is the point where I just gave up for the night and went to bed.



Day Three.
Some of the edges that I cut with the jigsaw came out a bit uneven so I wanted to smooth them out a bit.
Plus I haven’t used my little router table yet.



The mess the routing left.


Mobo Tray take two.
Up.


Down ready to bend.


Cooling in the jig.

Not bad for a rookie.


The other side.


I am not a 100% yet sure if I am going to use these for the top.


And now for the outer shell.


First Angle. I apologize for the lack of pictures here I was working fast and also some came out blury.


Second angle.


Third.


Cooling in the jig.


Fourth angle.


Cooling all together.


Ah crap. Another fail. As the heater got hotter and hotter I didn’t pay enough attention and it bubbled up a bit… Fail.



Here it is all together.



Top angle.


Coke can for size.



That’s all for tonight I am beat. Hope you guys like it.
 
Where did you get the plexi glass bender? But Cool project so far, interested to see more.
 
I absolutely LOVE 80/20. I use it in a lot of fixtures at work because it is so easy to work with and adjust. That quick frame stuff you're using is really great too. I wish they made the QF in a size smaller than 1". That'd be handy for smaller scale projects like this.

Nicely done man. Really great work so far. I like seeing people doing something a little different. :)
 
Good job! You are doing good! Stuff like cutting pieces to short is par for the course. I always order extra material for this reason. Also, bending stuff and compensating for thickness, and the radius of the bend can be a PITA. I would expect to do it at least twice! Haha.
 
Thanks for the encouraging replies guys.

I got the bender from amazon the company that makes it is called FTM, Inc.

Cmadki, I completely agree. I was looking for something smaller than 1'' but I came up empty handed.

The goal was to try something, fail a lot and learn a ton. I am going to have to put the mod on hold for about a month or two. We are finishing the basement and I am getting foot surgery. The workshop is currently packed up. I will be back at it in somewhere in the spring.
 
Any updates for us? I'm curious to see how this is coming along. You've inspired me to take on yet ANOTHER custom case build. :D
 
Not much of an update.

Our basement is being finished so I had to focus on the prep work for that. Also, I had my foot surgery about a week and a half ago. I am recovering fine but I will not be able to put any weight on that foot for another three weeks. It will be at least another month before I can do any work on the mod. Sorry to disappoint.

Cmadki4 I am looking forward to the new work log. At least it will give me something to do while recovering.
 
crowat said:
Not much of an update.

Our basement is being finished so I had to focus on the prep work for that. Also, I had my foot surgery about a week and a half ago. I am recovering fine but I will not be able to put any weight on that foot for another three weeks. It will be at least another month before I can do any work on the mod. Sorry to disappoint.

Cmadki4 I am looking forward to the new work log. At least it will give me something to do while recovering.
Click to expand...
I pray a speedy recovery for you! You may be back in action before I get a chance to make any significant headway on a project of my own. Got a 2 week old in the house now and she demands a lot of attention :)

Get well, get strong, drink milk! :D
 
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