Project Numero Uno (Xbox 360/ATX Case)

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This will be my first project so will be a big learning curve but hopefully I can still conjure up something which looks good – It will involve and Xbox 360 Slim & an old atx case which I had laying around.

Both the 360 & case have their own ‘issues’ so it will be quite a tricky build. Even putting a modern setup inside the case would’ve meant it needed some modding, but using a 360 just makes things a little harder but hopefully it’ll all work.

The final step will be to watercool this, and yes I know I can’t OC it, but it’ll be a good introduction to WC’ing so I can learn the basics etc.

Everything in this build is new to me, even Sketchup & photography but should be possible to get a general idea of how this looks currently and how it will look completed.

The pictures will be taken with a Fujifilm L55, so if anyone can give me any tips for producing better quality I’d be happy.

frontlc.png


Top Bay: 3 switches & XPSC temp display
Middle Bay: Xbox Drive
Bottom Bay: XPSC Bay Res (might change this)
Floppy Bay: Xbox “RF Board” – 2 USB ports to the right
Underneath is the fan grill I’m hoping I can cut out with a dremel.

Both floppy & drive bays will be covered with perspex and then a sheet of white di-noc carbon fibre over the top.

Colour scheme will be mainly white with some added orange and then the white di-noc carbon fibre used in the appropriate areas.

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Case all stripped down, with a very nice tint of yellow, mm..

casefront.jpg


caseside.jpg


caseinside.jpg


So onto the build, the first things I wanted to solve were mounting the motherboard (drilling the holes & modifying the I/O panel) & also extending the DVD power cable.

I didn’t have a camera from the start and was sometimes too eager so apologies for any that are missing but shouldn’t affect the log too much.

The original cable which was only 9.5cm but needed to be 32cm
dvdcable1.jpg


An old IDE floppy cable used to extend it
dvdcable2.jpg


The final product, albeit not great, it’s works. Splitting wires in a cable and ensuring the connectors were all aligned the same was damn tricky. As I plan to use some sleeving on this build I will have to either re-do this, or buy an extended one.
dvdcable3.jpg


The next step, motherboard mounting – this threw up a few issues, firstly because I didn’t have the tools to tap holes but mainly because of the indents in the tray, 3 holes I needed were above them, which meant I had to fill the area with something strong that I could drill into.

The savior!

repairputty.jpg

This is actually pretty good stuff, and will be used a lot on the build where I need to cover holes.

mobo21.jpg


The grey blu-tac lookalike is the putty, and was also used to fill the old mobo holes so it will look better when painted. You can just see the putty on the bottom for the bottom left hole.

The I/O panel cut so that all ports are accessible, and some electric tape just to be safe. Eventually all the brackets will be remove and filled in with perspex covered with white di-noc.

iopanel.jpg


Next part involved fitting the DVD drive into the case, which as stock is a few CM too small, so I salvaged something which was orignally in the case, a really old DVD drive. In order for it to fit, the side screw mounts had to be filed and the “circle” removed with a dremel (only 2nd time using one) and surprisingly came out pretty good.

Before:
optical1.jpg


After:
optical2.jpg


Will be secured using some strong double-sided foam tape which will hopefully stop the vibrations.

DVD Front & Back

dvdfront.jpg


dvdback.jpg


Still needs more filling off so it fits better as theres still a few vibrations when I tested.

Some USB ports taken from my existing PC will be used in the case, and had to find a convenient place to put them.. the location for a manufacturers logo, why not..?

usb1a.jpg

Apologies for the quality, was eager to do this so the photo was taken at night time, which my camera dislikes..

I was hoping the drill holes wouldn’t go all the way through but never mind, the area will be covered with a small piece of white di-noc anyway.
usb2b.jpg


Onto getting the Xbox running of an ATX PSU, which was key for the build. Firsly de-soldered from the Xbox PSU, crimped on ATX pins, and inserted into 24pin socket. Really wanted to solder to the motherboard, but wasn’t 100% with that so went with the safer way, which doesn’t look as good, but hopefully can be tidied up and eventually can do it as I had orginally had planned.

crimper.jpg


powercableq.jpg


One thing I learnt here – the pins that come from ******(UK store) are crap, really.. bad. Out of 20 I don’t think any went perfect when I crimped them, and I tried both slots on the crimper, but the insulation ‘wings’ would either break off in small slot or just fold over each other in the larger slot.

xbuild3.jpg


Last 3 photos taken in the dark so not as good as normal

Cable management is a big issue here, will have to dremel out some holes and buy some grommets.
 
Thanks :) It should be possible to make it look nice, with lots of jb weld + putty to cover up some holes I don't need it should look much cleaner.
 
Removed PCI brackets so I can fit in a piece of perspex:

iobefore.jpg


ioafter.jpg


Not so hard, but job done! A4 perspex is 297mm x 210mm, and what I need is 305mm x 110mm, should be able to get around that one hopefully.

Those cuts were done with a cheaper version of a Dremel, made by Silverline, which worked just the same, so if anyone is on a budget it’s a good choice.

To be able to fit a 120mm fan in the rear I had to mod the I/O panel and hope JB Weld would save my a$$. The current space is only 118mm, maybe could’ve squeezed it in but would’ve vibrated a lot.

bpbefore.jpg


2 Rivets drilled & small piece removed.

JB Weld’d! (fingers crossed)

bpjb.jpg


I should probably stop taking photos in the dark, but not so much light this time of year, and got to use that time for modding..

Only a small update as I've been messing with the overall plan but should be a bigger update within a week.
 
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Covered up holes in front that I didn't need with JB weld, and sanded with a dremel, much quicker than by hand

jb1l.jpg


Marked out holes for front & rear fans

front1iz.jpg


back1pa.jpg


Both cut out

front2pe.jpg


back2mn.jpg


Quite happy with the results as I haven't cut much with the tool before

Marked out hole for the fan, will use some perforated aluminium to cover hole.

frontfan1.jpg


Didn't have much success last time I used a dremel on plastic so just drilled lots of holes & cut around with a hacksaw blade

frontfan2.jpg


Just realised the JB that I used to hold the I/O shield in place has broken off, I guess the vibration from cutting so close to it caused this.. Will have to re-do but not sure what to us

Rear vent holes covered with JB and sanded

ventsl.jpg


At time of doing this the front fan was doing to be an exhaust, but recently learnt that having it as an intake and creating 'positive airflow' stops dust build up so may have to undo this.

Side window marked up & removing the vents to use yet more perforated aluminium, should look much neater

rightpanel1.jpg


Vents on other panel will have the same treatment

leftpanel1.jpg


Cut out

rightpanel2.jpg


leftpanel2.jpg


Decided to make a new disk drive mount, using another old drive but make it into a bracket to help reduce vibrations & noise. Marked up 2cm either side, should be enough

drive1j.jpg


drive3.jpg


Some connectors removed off an old mobo and mounted onto the RF board

rfboard.jpg


Made a mounting for the switches and temp display, will be cut into the perspex in the final build but this is just for testing purposes.

tempdisplay.jpg


Anyone know where to buy those rectangle mobo grommets? Last thing I need to add to mobo tray before I sand it all down.
 
I also have been looking for some of those grommets, Corsairs US site sells them but couldn't get a payment to go through. wont link due to possible breaking forum rules.

Also the Coolermaster US NLstore type thing has them.

I can't find anywhere else so if you find some let me know.

the other option is to make some
 
Update is a week later due to lack of free time.. so lets get straight into it!

Had to re-do the front fan hole as in my lazyness it wasn't central

casefrontfan.jpg


casefrontfan2.jpg


Perforated aluminium marked up to be cut

casefrontfan3.jpg


Cut out

casefrontfan4.jpg


Rather luckily the holes in the alu line up perfectly to make the fan central, just had to widen the holes to 4mm so the rubber mounts would fit – first bit of luck on my build..

Not mounted into case yet, may buy some new expoxy as I really dont like JB weld.

Cleaned up edges for vents and side window

leftpanel2.jpg


Perforated aluminium cut down to fit – Was a bit of a pain cutting with a dremel, didn't get a 'clean' cut

perfalu.jpg


rightpanel2.jpg


Will use some rubber edge trim to make it look neater

Going to make some case feet from clear perspex – Used some 'special' plastic cutting discs made by dremel, but they were no different, still had same effect as normal ones.

feet1.jpg


feet2.jpg


Will be putting an orange led inside with a bezel, so that I can secure it to the case – Guess it's the easiest way

Soldered USB ports

usb3u.jpg


Decided to use some orange 5mm perspex to make a mobo tray and use some 3mm for the I/O panel and front bay cover. Mobo will be last thing I do as I need to find a good mounting method

Got both pieces for front & back marked out

orangeperspex1.jpg


All cut out

orangeperspex2.jpg


The small thin pieces are for the outer edges on the I/O panel to make it look neater

Hopefully not much modding left before I can get onto finally assembling this, took much longer than expected, mainly due to having to do a lot of work outside and weather is never ideal.
 
Minor update – slightly disappointed I didn't get that much done.

Alu fitted into right panel:

rightpanel4.jpg


Had some issues with the left panel and front due to the size it was slightly tricky to get all the sheet level, will have to re-think it a little as I have no clamps etc to use.

Front fan cover:

Piece of perforated alu cut & bent

frontalu1.jpg


Another simple idea of securing to the case, cut a few tabs that will go through the case - damn lots of work getting it to fit right, constant small adjustments but worked in the end.

frontalu2.jpg


..lots of perspex sanded last few weeks (very time consuming)

Front:

perspexfront.jpg


Rear:

perspexback.jpg


Case feet made:

feet3.jpg


feet4.jpg


Simple idea, 4 pieces – LED bezel goes into the 3 glued together & the last piece is glued on top holding bezel in place so I can secure it to the case.

Had hoped to sand and primer it all, but poor UK weather as usual prevented this.
 
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