Small Form Factor Case Mod

I wanted to build a custom firewall/router PC. Something small and compact, and which would use up some of my old computer parts.

Let's see what we have to work with?



What a ridiculously bulbous case! No wonder Packard-Bell went out of business.

Ah, that's better: The metal part of the case isn't too bad. We can work with this!

Drives? Who needs 'em! With the drive bay cut off, I shortened the case by a third. Then I used new rivets to attach the old top at the new height. Very clean - looks almost stock.

Unfortunately, the side panel now doesn't fit.

Mr. Side Panel, meet Mr. Angle Grinder.

I knew I'd never be able to cut a perfect edge with the grinder, so I riveted aluminium bar stock to make a skirt to stiffen the panel and mask the imperfection. If you can't make it, fake it!

Now I just need a face plate.

Look! A perfect fit - other than being ginormously tall. I really like the styling on this face plate better though.

We'll just cut it in half too. Uh oh... I didn't account for that big hole on the top of faceplate after it's cut.

What better way to fix the top of the faceplate than with the, er, top? The steel files in the background: I used those to trim the cuts so they'd glue together flush. I have mad skills with files. You can see here there's still going to be a seam no matter what I do.

Time to pull a design trick with the magician's old standby: indirection! Since I can't make the seam impossible to notice, I'll do the opposite and call attention to the area with a little decoration. Who knew strap iron could be so appealing? Earl Martin calls my style "industrial art deco," which I think has a nice ring to it.

Here's how I laid the parts out to fit them in such a small space.

The finished case mod in all it's glory, sitting as the capstone on my pyramid of computers.

A Curiously Chocolate Radio

I've been saving Altoids tins for years. They're full of project possibilities: how much electronics could you cram into one? What neat things will people see when they peek inside?

From the outside this looks like an ordinary Altoids tin. But what's under the cover?

Why, it's a shiny pocket radio!

I got the circuit board out of a cheap FM radio, but I added the batteries and speaker. (The original radio only had head phones.) It turned out to be very difficult to get the antenna to work right. The original radio used the head phones to double as a loop antenna, but the speaker I replaced them with doesn't have long enough wires and wouldn't get any reception with the metal tin surrounding it. I solved it by running one leg of the audio out the back as an antenna wire, and I grounded the other side of the audio to the metal case.

Now the radio gets better reception than it did even before I hacked it!

The chocolate brown theme of the tin reminded me of old wooden cabinet phonographs, so I thought it would be neat to make the radio so that you prop the lid open to use it, as if it were from that era.

The speaker is held to the lid with foam tape, which keeps it from buzzing. The circuit board is held on one side with foam tape and screws on the other side, and the batteries are in a Radio Shack AAA battery holder, also secured with foam tape. I used 190 proof Everclear to pre-clean the inside of the tin, so the foam tape would stick tight.

I'm pleased with how this project turned out. It's one of the few projects I've actually seen through to completion in years - a testament to the wisdom of choosing a simple project. And it's something I will actually use!