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Project Set-Top-Box Windows Home Server

MurphysLaww

Limp Gawd
Joined
Feb 12, 2007
Messages
182
I know this has probably already been done several times, but here is my shot at converting a Cable TV Set top box into a Windows home server

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I'm not going to be able to get an optical Drive in there, so I'll be installing the OS from an optical drive connected remotely and then remove it.

Started with an old Shuttle XpC that I could have used, but it's a little taller than I'd like, so I thunk... Why not the old Set top box I had laying around from an old cable company?

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Pulled the STB stuff out and, wow, there really isn't much room in there. it's only about 60mm high. I'm still searching for a 1U server CPU fan for an AMD 462 Socket. Found a couple, but it's still going to be tight. As it is I'm going to have to mount the power supply to the outside rear.

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Once I started tearing up the Shuttle, I realized how really nice and well engineered the XPC's are. The major computer manufacturers could learn a lot about engineering from those guys. The solutions they have made for saving space are pretty ingenious. That and even 4 years later, the box is still in awesome shiny aluminum shape.

had to cut the side of the Set top box out for the I/O connections, need to revisit that with the dremel later.

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Cut the Hard drive mounting bracket up from the shuttle and figured out positioning of it. Eventually it will have a 40GB OS drive and a 1 TB storage drive, and after that, probably just two 1 TB drives.

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The way I initially wanted to situate it wouldn't work, laid down a thin, neoprene-like mat that comes in between the screen and keyboard on gateway laptops. It should protect from shorting along with the plastic standoffs I used.

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I'll mount the PS to the back plate, there are screw holes already ready for it. It should be solid, if not especially aesthetically pleasing

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So this is where I'm at now. I'll add the front USB/1394/optical SPIDF panel from the Shuttle case, to the right side of the case eventually.

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I've just removed most of the components from the breadboard that all the button components from the front panel press to. I'll be mounting the On and reset buttons to two of those, and then depending on what type of LCD that I can find to fit in there, possible a few buttons from the LCD for functionality. I'll mask the tinted translucent plastic and repaint the black plastic to get rid of most of the original button labels. I'll probably only track a few temps and fan speeds on the front LCD, unless there is more advanced reporting available in Win Home server. When it's done it ought to look pretty spiffy.
 
Motherboard setoffs mounted, Powersupply hardmounted.

Still need to sleeve the powersupply.

Still bouncing around the possibility of mounting a slim, slot load optical drive, exiting to the side, left of the hard drive.

This would only allow one hard drive then. Not sure how many DVDs can be ripped to a single 1Tb drive as opposed to two.

Still researching LCD Panels. Since this is only going to be a Win Home server box, The main functions I want the LCD to display are H/D space, H/D Temp, etc.

It'll go in here with the HTPC, replacing the sony surround sound system. It'll be funny when people ask why I have two set top boxes.


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looks like this will be the CPU cooler. It'll be about 40mm tall which is about what I have.


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Still researching LCD Panels. Since this is only going to be a Win Home server box, The main functions I want the LCD to display are H/D space, H/D Temp, etc.

CrystalFontz 631, different colors to choose from, 4 programmable button for different display information, several colors to choose from, 3 1/2 in size
 
Looked at the crystalfontz, It's definately a possibility. I guess you need to use LCD Smartie for it or something similar.

I'm leaning towards the Silverstone MFP51, as it's readily available, and If it's not what I want, I can use it in my desktop. It also has a remote on/off feature which will allow me to not have to rewire the on/reboot switch.
 
This looks like it will be a fun project. Keep us posted. :)
 
Wow, come to find...

I super-suck at sleeving:

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That CPU fan won't fit by about 5mm so, since this is going to be a bargain job, I'll be cuttin' the top for it.

it'll probably be a bit better for airflow that way anyway.

I'll be mounting 60mm fans in the lower rear corner behind the M/B and in the front between the H/D and M/B. front pulling in, rear pushing out.
 
Looks like I'm going to use the LCD from my g15 Keyboard. There are quite a few apps already built for it, and it'll cost me less to replace it than most of the LCD set-ups I've been looking at.

Hopefully it will work without the Keyboard attached to the circuitboard.

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looks like the LCD will work just fine with the keyboard not attached.

Unfortunately, I'm going to have to mod the face of the set top box quite a bit to make it work.

gonna get some bondo...

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Nice job so far!

WHS likes a big primary drive and from what I've read for my WHS build a month ago it sounds like you'd be well off to just ditch the 40gb drive initially. Add the 2nd 1tb drive when you get it and add it to the pool.
 
this is lookin good :)....im thinking about doing something similar...ive got a really big set top box outside that is busted :)...

Definetly subbed to this one
 
Realized I haven't ever posted a pic of what the front panel looks like.

I'm going to remove the entire smoked plastic panel and cover the LCD with a 4mm thick piece of lexan that came from the Xpc front panel. All the buttons will be gone after bondoing, to be replaced by the button panel from the G15 keyboard.

Since I'm using the G15 LCD, I am thinking I might go away from the win home server and just put XP media center on it and use it as a CD/DVD player as well, just with all the media already on the system. With a little tweakin, you can make windows pretty much function as a home server anyway.

I just don't want to waste that neato volume potentiometer.

dctcomcast1dc5.jpg
 
Now the "real" modding begins.

Up til now it's been kind of cut and paste. Have to bondo the depression from the old smoked plastic LED cover, and all the button holes so that the whole face is smooth, then cut out and mount this lexan piece from the XPC front bezel. The LCD will sit behind this.



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Then, have to graft the old keyboard button panel to the faceplate and mount the pcb behind so the buttons make contact again. It's probably going to be even harder than I think it will be.


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done with the dremel work on the keypad, came out so-so. It ought to work.

I'm taking a VB & .NET programming class this semester. Hopefully it will get advanced enough that I'll be able to do some basic stuff with the Logitech SDK for the LCD.


picture21we3.jpg
 
Well,looks like the keyboard LCD isn't going to work.

LOL, ohh well. The ribbon cable isn't going to be long enough to allow me to mount the button module and the lcd side by side. It looked long enough , but it's about two cm too short.

I'll have to save it for another project. Crap, that was a nice keyboard too. I'll probably get the new G15, as the folding LCD was too tall to fit in my keyboard tray and it was too wide for the tray as well.

I'll figure out a way to graft it to my CM690 case in some way.
 
sad to hear about that screen not working :(...

i just went and looked out beside my garage to see if my old set top box was there....it was...and guess what...

Its the Exact Same one as yours :eek: .....i thought it was bigger then it is...but ill try it anyway lol.

GL with the build.....do you mind if i borrow some of your ideas beins we have the same box?
 
The ribbon cable appears to be proprietary to the G15.

I guess I may just go back to the idea of using the silvestone/Imon LCD. I can still pick one up for $80ish. It comes with a mediacenter remote, so I'll be able to do remote functions, which would be cool.

I still may be able to use the G15, but it wouldn't be very elegant. I would have to use the orignal lcd bezel and attach it as a flip up panel, more or less how it sits in the keyboard itself.


Anyone can use any of my ideas/setup, I don't do this for a living.
 
Well, it's running. Just made a fresh install of Ubuntu, and it's running nicely.

Be picking up the Silverstone/Imon LCD in a week or so.

Been thinking again about Mythbuntu, but will probably end up with MediaCenter, as I have no Ideas what kind of issues I would run into getting the IMON panel working in Ubuntu.
 
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