Lean and Green - modular dual PC scratch build

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HTPC little front power switch section with a lot of detail in multiple layers.
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HTPC side detail panels.
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Pattern panels to friction fit into the coupling piece.
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First I made them a perfect fit.
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Then cut the patterns out.
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Put in place.
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How they look with the extra detailed pieces.
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Loose fit.
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3 more to go before regular progress.
 
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Thanks everyone, I'm quite excited to be getting back onto this one, never taken a break this big from a project before but I've never done a project this labor intensive before so it figures. :D



Dropped the ball on the daily updates, dermatitis has come back due to prematurely stopping applying the ointment but I hope it goes away ASAP & I will try to not let it prevent me from making new progress.

Luxury jumbo power switch because I had to use my pinky to switch Stealthlow on (16mm vandal switch) big 40mm ball based on how vandal switches work, :D I wanted it to sit flush through the layers so had to countersink the insides of the layers with files.
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Designed & made a bunch of replacement fan controller knobs because the stock ones were plasticky & boring plus I wanted to see if I could even make them with being so small. :D
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Made the rear IO/expansion motherboard tray pieces for the ATX & the mini-ITX with low profile expansion card size, drilled expansion card mounts & used hot soldering iron to sink brass thread inserts into the holes.
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These motherboard trays were remakes, previous ones were 1mm off with not accounting for the IO shield that comes with motherboards.
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The assembly for the marble button.
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Fixing the button assembly in place & fixing more panels together.
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Squigly on bit-tech pointed out the spindicator LED mod to me & Riekmaharg2 on bit-tech really helped me by making the electronics part of the Spindicator leaving the LED soldering to me, I'm a total newb on electronics but seem to be good & happy with that fact other than knowing a large chunk of my imagination is untapped potential so I blag myself I'm happy about being an electronics newb, it works somehow. :D
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Simplified the wiring a bit by making a copper washer I drilled holes for the negative pegs of the LED's to go through & I later caked liquid electrical tape over it all making it look real messy but insulated it all to prevent short circuits, cut a bunch of acrylic discs & pasted transparent vinyl's to them so I can select the colour with whatever looks best which I won't know for sure until final assembly.
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Spindicator in action.
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Few videos of it made with a kodak pointy shoot with 720p high fuzzyness, not high definition :D want to upgrade my canon eos 1000d to a 550d so I can shoot nice clear video because videos can say a lot without saying a word & I like that a lot. :D



Made a case for the spindicator electronics which only just fits in next to the HTPC PSU.
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2 more to go. :D
 
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I slipped up on the updates so to get it right here's another 1.


Mounting the coupling plates to the bottom plate, had to retrofit templates in place with not including mounting points in the initial design, this made fixing everything together a lot more difficult.
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Mounting support bars to the top of the coupling piece, wanted to use 3mm but was all out so went with 6mm bars.
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Back to the squirrel feet adding pegs to the front making it a good solid fit, they are also fixed in on the short ends so they don't move about.
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Optical plate mounting.
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Added rod & grub screws to bridge the gap from HDD section to motherboard section.
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Added the layers to let the mini-ITX tray slide in/out.
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HDD sliding slots to replace a HDD box I made but wasn't quite right.
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Fan perch & more sliding slots.
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HDD trays.
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Sticking the slots in place & mounting them to the panels.
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Works nice but more work will be going into it so the power & sata plugs don't have to be touched & I just slide the trays in/out of place hot plug style.
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1 more to go, then I can carry on at normal pace. :)
 
Soldato
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I have no idea what that Spindicator is or what it does...I love it though!

can you explain, the videos left me none the wiser! :D

Edit - Googled it, cool stuff :D
 
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I have no idea what that Spindicator is or what it does...I love it though!

can you explain, the videos left me none the wiser! :D

Edit - Googled it, cool stuff :D
Is isn't it, just glad I had the help on making the bit I have no knowledge of, thanks Sin. :D

Looks absolutely astonishing :D Subbed
Thanks benccritchley, I can't quite imagine how it's going to look complete but hopefully it makes my jaw drop. :D
 
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Final catchup update. :)


Fan perch, fan just slot on top of it for a good snug fit that has no movement but can be lifted off for maintenance.
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More work on the optical plate.
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Both pieces in place.
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Now the rods for the front corners, they all had to be ultra precise lengths & some of them needed drilling directly in the middle so I made a drilling jig to help on that, typically need a lathe for this kind of drilling, not got one so had to improvise.
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Now, the piece I love, aluminium blades on these prolimatech fans, expensive, noisier & not as good performance as akasa apache fans but I couldn't resist the aluminium fan blades, perfect for the custom fans I'm doing, full aluminium fans, yes please. :D
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First bunch of rods went in OK, the tapped ones.
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The 3mm rods though I drilled too close to the edge of the panels so 3 easy panels need remaking which will let me fine tune the design of these corner rod parts to be spot on.
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Work on the curved & bent front support piece & a fan mount for the ATX system which I did some rough but good enough milling with the drill press.
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The sharp bends I wanted made doing the curves smooth really difficult, might remake the piece from 0.5mm sheet instead of 1mm so I can do it perfect & instead of using screws to mount it, JB weld to the support piece.
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More work on the curved front & that brings this up to date.
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Few bits to remake & tweak, then I can start making new progress, already started on new bits though so should have good new progress along with fixed sections for first new progress update for a year soon. :D
 
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Back to normal progress, completed a couple of new pieces for the ATX system, the expansion area cooling mount, used lexan because I had no clear acrylic.
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It's been a fair while since I designed this & realised the panel I made would have covered up anything inside too much & also cancelled the fan ducts so I could have more expansion height space if needed so I tweaked the design to properly accompany the changes & made a new one.
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Thanks :D


This has been my most riddled with delays project so far but it's still coming along.


Making spacers.

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Square bars for the ATX framework.

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Disc sander broke down so slapped a face on it & got a new one.

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All 28 fan layers done.

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Front & rear ATX panel remakes, needed extra internal space for the change of cooler & fancied a different front, but a nasty deep scratch revealed itself on the rear panel when I pulled the protective backing off, that'll need a heavy sanding session.

Subtle differences.

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Bought a sheet metal roller for doing smooth precise curves since I had to buy a new disc sander, step backwards, 2 steps forwards. :D

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Some change of direction because I had to make it likable for myself again for 2014.


One piece triple 140mm fan component which slots & clicks into the frame.

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Out the box layered fan along with desktop saver stilts.

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Changed the pedestal to a shorter shelf unit without walls because of the xbox one being a wide load with an extension to the top of the HTPC for a ps4 shelf & a TV mount.

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Designed a multi layered HDD backplane for the HTPC.

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Yep I still have the silly stack as an option because I at least want to photograph that option since that was the idea from the end of 2011.

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Focusing on doing bigger chunks of progress from here now for updates so they'll be few & far between rather than bitty regular updates, wish I did this from the beginning but I didn't so oh well. :D
 
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