Project : Zotac ITX Rebox

bugeyewrx · 8 Nov 2011 at 16:37

My first scratch build was this .....

Project log here

It's a HTPC that uses a ZOTAC IONITX-P-E , a pico psu and laptop brick and runs XBMC to stream from a server . When I built it I needed a graphic card with an analogue out so that I could connect to a crt television . Now that I've joined the 21st century with a tv with a hdmi connection I don't need the graphic card . I added a vent above the cpu fan and that seems to work well enough for cooling .

The card now lives in my second project , this another HTPC with an ASUS AT3IONT-I Deluxe ....

The project log for it is here

So there is no need for the extra space I thought it was time to make a new case for it . I was happy with the look my second project so I'm going for the same sort of look only smaller about 200mm by 200mm by 70mm .

Dubious sketchup picture .....

The main difference between my new build and the Asus build is really the constuction . I want to make something that is simpler to build and that I can get parts laser cut for so that I can make more for friends etc .

So 4mm acrylic it is then

First part is the base and internal sides . I want to do this as one part with the feet as part of it .

I've not bent acrylic before so all a bit experimental for me .

First a jig ...

First trial piece , only a 50mm wide strip .

I didn't really like the sort of double radius at the point shown by the arrow .

So I had another go with an extra clamp ... you can see the tighter curve on the right .

Going to try out a full size one now

bugeyewrx · 8 Nov 2011 at 16:39

So first attempt at a full size one .... sort of good and sort of bad

Blank in the jig about to get heated ...

First bend ... waiting for it to cool .

And the second .

So all sort of works but a couple of problems ...

I think I'm taking out of the jig before it's cool enough , it's hard to see but the sides aren't at 90 degrees . I think it's distorting as it cools unevenly . Easy fix I think .... leave it it longer .

Second problem , the ends of the acrylic are bulging out . I think my jig is too tight and it's forcing the acrylic out as it bends , you can't see it in the picture but there is a sharp line on the inside of the 'foot' where the jig is pushed into it .

I think I need to radius the parts of the jig that push into the acrylic .

bugeyewrx · 26 Nov 2011 at 13:31

Forgot to update this one :rolleyes:

So I spent an afternoon working on this project ....

And I finally got one the right size and pretty square

But I've run into problem if I want to make a few of these .

They all come out a slightly different size . Not by much .... about 1mm but it would mean that various parts of the case wouldn't line up

I think the triple bend is just too complicated for me make with any sort of consistency .

A bit of a rethink is needed

bugeyewrx · 26 Nov 2011 at 13:32

Strip Heater

So I've got a new plan for this , same sort of look but a couple of changes to the construction .

I've got some 2mm acrylic now so all I need is a strip heater . Rather than start a new thread I thought I'd put in here

First step I dug out my old foam cutter and power supply from when I made and flew RC gliders . Still working after 15 years but I suppose there isn't much to go wrong with it :lol:

I want the wire to stay straight when it gets hot and expands so some sort of tensioning thingy is needed ....

Brackets .

Some bolts with springs .

Tensioning thingy fitted with the wire and electrical connection

Test run .... it's hot and it's straight

Seems there is something that can go wrong .... just after I took the picture the wire snapped :worried: luckily it's not under much tension so I didn't get whipped by a bit of red hot wire , maybe a bit too much heat for my 15 year old wire :duh:

Anyway running repair until I get some new wire .

Finished

And a bent bit of acrylic .....

And if you're really interested a video of the tensioning thingy in action ....

bugeyewrx · 26 Nov 2011 at 13:34

So a quick rough and ready test run of my new plan

Internal bit , I'll make the corner cut outs neater on the real thing .

With the cover .

So far so good , the parts are square and the right size

The only problem is the top sags slightly . I though about fitting a brace to support it but I'm trying to keep everything as simple as possible . Second idea was to inset the front panel instead of fitting it on the front but then I lose the clean look of the front .

Then I realised .... turn it through 90 degrees inset the sides . Clean look to the front and support for the top

redfist · 26 Nov 2011 at 18:41

Impressive so far, liking this project. How much are the materials your using and how long does it take to bend?

Kodiak · 26 Nov 2011 at 20:14

I like the look of this project. Scratch built cases are always more interesting that other builds.

BTW, what are you using to heat the acrylic sheet? Ever tried bending a large raduis with acrylic?

Hyburnate · 26 Nov 2011 at 20:25

Kodiak said:
I like the look of this project. Scratch built cases are always more interesting that other builds.

BTW, what are you using to heat the acrylic sheet? Ever tried bending a large raduis with acrylic?

His using a heatgun

bugeyewrx · 26 Nov 2011 at 22:12

redfist said:
Impressive so far, liking this project. How much are the materials your using and how long does it take to bend?

I'm not sure on material costs yet . It doesn't take long to make the bends . If the wire is up to temp it takes about 45 secs for the 2mm acrylic to be bendable .

Kodiak said:
I like the look of this project. Scratch built cases are always more interesting that other builds.

BTW, what are you using to heat the acrylic sheet? Ever tried bending a large raduis with acrylic?

On the first case design with the foot I was using a heat gun on the new one I'm using the strip heater I made .

bugeyewrx · 27 Nov 2011 at 16:54

Today's progress ....

Now I'm a bit more certain about where I'm going with this I started on an accurate template for the base .

First proper go at a base .

Made a jig to hold everything square while gluing the sides on .

Bit of weight to hold everything steady .

Sides stuck

And a trial fit with the old top .

Now I know I said I wanted to keep the front face clean but now that I look at it I rather like the white edge of the top showing .....

neil_g · 28 Nov 2011 at 11:57

excellent work, i reckon people would buy those you know..

Hyburnate · 29 Nov 2011 at 21:33

I would ^

Tokin · 4 Dec 2011 at 16:14

Id buy one 100%

bugeyewrx · 5 Dec 2011 at 19:41

neil_g said:
excellent work, i reckon people would buy those you know..

Hyburnate said:
I would ^

Tokin said:
Id buy one 100%

Thanks guys .... good to know I'm getting it right

Mini update

I've been working on fine tuning the bending of the internal part of the case . I'm trying to improve the accuracy of the tabs etc .

So yet another template , turned through 90 degrees so that the coloured panel is on the front . I've also put in the mounting points for the standoffs etc

A slight change to the strip heater ... these bits hold the wire in position more accurately .

Almost there with the corners

bugeyewrx · 7 Dec 2011 at 14:22

So after many templates , jigs and remakes of templates and jigs and trial pieces and slightly different trial pieces ......

I finally feel like I'm getting this sorted :lol:

The internal and front and back bits for two cases .... both the same size ( the right size ) , both square and they match each other

So next to sort out is the cut out for the I/O plate then on to the cover and some sort of ventilation .

True_Scotsman · 7 Dec 2011 at 14:27

Looks good

Subbed

pyropetepete · 7 Dec 2011 at 14:41

Put me down for one as well.

Will you add an optical drive at all? Id love one to fit a slim optical, 2 SSD's

bugeyewrx · 7 Dec 2011 at 17:10

pyropetepete .... no room for an optical drive , now that I've done the cut out for the I/O plate you can see how tight it is on space .

There's 15mm under the mobo for a laptop hdd and a low profile fan .

Gangster · 7 Dec 2011 at 20:29

Very nice

May I ask how you made the strip heater?

redfist · 7 Dec 2011 at 20:47

Looks really good.

You mention there is no space but what if you used some thing like a slot-loading drive:
http://www.sony-optiarc.eu/products/bluraydrivesnotebooks/bc5640h.html

The size seems quite small (128 mm x 12.7 mm x 129 mm) and with this I think it could improve this amazing build! (not that there much room for improvement!!)