CrashBox

[KikBox]

For now I am calling this the CrashBox Project but the name and theme is still up in the air. The best place to start any project is with a plan, so here is the rough plan for this box including pictures, measurements and a list of components I would like to incorporate into the design.

First of all, yeah, I know this is a really old case! I got this in 1997 and used it for my personal computer for many years. When I took it apart there were huge dust bunnies behind the bezel...nasty. I had to beat them with a stick just to make sure they were dead!

It's a classic Aopen HX08 tower and is very unique in many ways. The power supply is situated just above center in the case leaving a lot of room above it for fans and components. The case is setup for 2 80mm exhaust fans in the top rear which is actually quite good for the time it was built. The case did not come with any fans so I will be adding these after I punch out the grills that have been stamped into the case.

There are 2 hard drive cages, one below the 5.24 drive bays and one in the back above the PSU. I like this situation a lot and I am going to strive to put all of my drives above the PSU so that I can have all open space over the motherboard. Eventually, I would like to convert this box to water cooling so having all that open space will be nice. There is a 3.5 floppy mount on the top of the case, I plan to use it... but not for a floppy.

The case is a tank. With all steel construction and measuring 24" tall the whole thing weights 20-25 pounds with nothing in it.

What it is for?
The system is going to be a mobile LAN party server. As such, it will be responsible for serving our games but will also double as an entertainment center. It needs to be sturdy (not a problem), cool looking, and easy to deploy.

How will I accomplish this?
Well, I plan on installing an LCD screen so I can leave the monitor at home, which will help with ease of deployment. It will also have a built in hub so at least 4 gamers will be able to plug directly into the CrashBox at game time. The system will include a 5.25 bay stereo system for playing game sounds and MP3 file between games. I will be adding either case feet for stability or maybe wheels (if I can find something that won't make it tippy) and handles of some type for hoisting it in and out of the truck.

I think the first thing I should do is clean it!

 

[shadowlord]

sry, but i can't see any pictures

 

[KikBox]

Must have been a short burp with the IPS. I can see them fine and so can some other people...

 

[Dillusion]

i can see it fine....that case is waaayyyyy to big for life, lets see what you can do with it.

 

[KikBox]

Case Measurements
I have measured everything on the case and here are some of the details. I have included a few addtional pictures from other angles.

Other Measurements
The panels for this case deserve mentioning for several reasons. First of all I need to make sure everyone knows how they come off so that we take that into consideration during design. Naturally, the panels are also slightly larger than the frame:

Side panels: 15 3/8" wide by 21 1/2" tall
Top panel: 7 3/4" wide by 15 3/8" long
The case design requires that the top panel be removed before the side panels can be taken off. The side panels slide into channels both top and bottom starting at the back and sliding forward. I immediately realized that this was going to be a problem if I decide to install a window as the acrylic pane will hit the chassis and the panel will not be able to slide into place. So, I have modified both side panels so that they can be placed into the bottom track and tipped up into place. The modification works very well!

The other thing to mention about the side panels is that they are a super heavy gauge steel. I mention this because they could give my hole saw trouble and I will need to take that into consideration when the final design decisions are being made.

Here are a few more pics for your enjoyment! I am pretty sure that my current mid tower could fit into the motherboard compartment of this case.

 

[daedal]

I think we have one or two of these in the basement somewhere.
They used to be servers too.

Man, you get some dual-PSU sandwhich action going in there.

 

[TESLA]

I have the Antec model of that exact case; it really does have a lot of potential.

Although, I find it immensely funny that you wish to place an LCD within the case to help with deployment.

This case is by far the heaviest I have ever purchased; I really can not foresee moving it around that often.

The case is built like a bunker.

 

[KikBox]

I have the Antec model of that exact case; it really does have a lot of potential.

Although, I find it immensely funny that you wish to place an LCD within the case to help with deployment.

This case is by far the heaviest I have ever purchased; I really can not foresee moving it around that often.

The case is built like a bunker.

LOL...there is no doubt it will be a monster but all the better! Behold the majesty of the LAN server...

We usually do the LAN once every 2 months so it should not be too bad. If I really make it look badass I won't mind hauling it around.

 

[KikBox]

Last night I spent some time working on the case. I know that I am going to be mounting dual 120s in the front so I started thinking about how they should be mounted. I will be placing a piece of aluminum over the front of the case so I decided to cut away the front face of the chassis. I did this for 3 reasons:

1. I plan to use rubber grommets and U channel and having 2 layers of metal would make it hard to use these items.
2. Reduce the weight of the case because I am already going to be adding weight in the form of diamond plate.
3. It will be easier to cut my fan holes in a flat sheet of steel than in the side of a case.

I cut away the section of chassis using my jig saw. It worked great and cut even this thick stuff (1mm) like a hot knife through butter. I was very happy with the performance of the saw and I am confident this will be the ideal tool for cutting my windows. I was able to remove this chunk of steel in less than 2 minutes.

I still have to buy the stock that I will be bolting in its place. I will be using Socket Cap Machine Screws to hold it on but in the finished product may go with some kind of thumb screw if I can find something with a long enough post. I will be cutting a second piece that will be mounted over the steel plate but this will be nice looking diamond plate on stand offs. That's the plan for now but all of this is still up in the air.