Monthly Archives: July 2018

mounting the fans

The two fans (speed controlled by one of the touch sensors) are placed over the projector, to generate a flow from the motherboard zone to the left tower:

To mount each of them I used a steel bar and a bolt, to hang them on two roof joints:

The hanging system:

The fans were too big, so I had to cut one of the corners to fit them in place:

And finally these are the fans mounted:

assembling the PC and case lightings

Here I remove the dummy hard disk and I put two green cold cathode lights:

I mount the real hard disk:

A lighting test of the “infected sector”:

The PSU (mounting the PSU I discovered that the motherboard cable was too short.. I will make an extension):

The videoprojector:

I plug the hard disk molex (for now I have only one hard disk, so in the second slot I keep the opened hard disk):

And I start to connect the touch sensors circuit cable to the components:

Some lighting tests:

Here I mount a power strip too: (in the case are needed 4 sockets: PC, monitor, touch sensors circuit, videoprojector)

And this is the extension for the PSU-motherboard cable:

The final result:

Then I had to extend the 4 pin PSU-CPU cable too:

And these are the two extended cables connected to the motherboard:

Some other cold cathode lights:

To avoid lighting the green infected sector with blue light, for the circuit encasing I have covered with some blue tape 3 of 4 sides of the cold cathode tube:

for the top panel I used this 6 LED structure:

And then I can finish to assemble the PC and I turn it on for the first time!

starting to assemble the PC hardware in the case

And now it’s the moment of the final step: mounting the PC hardware in the case! 😀

[Note from the future: it was not the final step at all! 😀 Don’t worry if you see old hardware in these pics, this is the first version from 2008. Soon I will post the current hardware… (i5 6600k, RX 580, etc.)]

Here I’m disassembling the hardware from my previous mod “AluBT” (it was a similar concept: an all-in-one block with the case behind the monitor, all made in aluminium):

And now I can assemble them in the Kernel:

making the cable that links the sensors circuit to all the case devices

Now that all the components are in place, it’s still missing the cable that links the touch sensors circuit to all the various components in the case.

This is the starting material:

The relay for the audio mute button:

Power and reset connectors for the motherboard:

The switch to turn on and off the videoprojector:

This connector must be connected between the videoprojector and his PSU, in this way:


The molex that must be connected to the PC’s PSU:

The molex for powering all the cold cathode lights:

The fan connectors:

The sensors circuit power supply (the circuit must have an indipendent power supply, because it must be always active to power on the pc, even when the PC’s PSU is powered off):

Covering the wires with some heat-shrink sheat:

And this is the completed cable:

The indipendent power supply for the circuit (it belongs to an old mobile phone):

mounting the video projector in the case

…lol I was joking 😀 NOW arrives the mysterious device!

Do you remember that shape drawn on the PSU cover?
I made a big hole on the PSU cover with that shape, because this is the shape of the device’s base:

And this is the device’s base:

The device has a little speaker, so I made an hole on the case for it:

And for the first time in a pic, this is the mysterious device!

Now I do a simple engraving on the PSU cover:

The mysterious device is turned on… 😀

…and after the mirror, there is another technological device… a plastic bag!

Now it should be clear what is the mysterious device: it is a VIDEO PROJECTOR!
It should be a secondary monitor for the pc, projected on the front wall of the left tower.

This is a test of the projector (the projection is reflected from the mirror on the front screen):

And now I can show two old ugly pics from 2005, when I made a first positioning test of the projector and the mirror 😀 :

mounting a mirror in the case

Now it’s time to unveil the mysterious device! 😀

For this purpose, I must mount over the hard disk structure a very technological device: a mirror!

I glued some layers of poliver and a steel bar behind the mirror:

Then I covered the behind and the sharp edges with a printed drawing and some white tape:

The mirror position should be adjusted with precision, so I mounted it on this steel bar, to be able to rotating and moving it freely.

Well, now that you know that the mysterious device is a mirror, we can move on to something else…

mounting touch sensors, circuit and feedback LEDs

Here I mount the touch sensors circuit, the sensors bar and the feedback LEDs bar (during this operation I broke 3 sensors, that I had to remake…).

I put in place the feedback LEDs bar:

Then I mount the very fragile sensors bar:

…too much fragile… this is the first casualty (that will be followed by other two…):

I connect the proximity sensor to the circuit and I close the side panel:

Turning on and testing the sensors:

Here I must remake the 3 broken sensors (2 hours of tension… I was feeling like defusing a bomb 😀 )

And finally the assembled circuit with all the sensors working:

A couple of pics of the sensors in the dark:

assembling all the chassis components

And now, the most important phase of the entire project log, a moment that I waited for 2 years!! I can finally remove all the white protective films from the panels and assemble all the case components, so I can see for the first time the real appearance of the transparent chassis and the internal structures, that until now I had only imagined 😀

And these are the phases:

removing the film from the stainless steel base (I had to remove and remount all the joints)

Cutting the rounded corner of the steel base:

One by one, washing and assembling the walls of the outer chassis:

And for the first time, the outer chassis assembled without the protective films! 😀

two L shaped bars to fix the PSU on the base:

And now, a lot of pics of the assembled case! 😀

The outer chassis:

Assembling the internal structures:

Here I put the bolts on the motherboard structure:

The sensors circuit encasing:

The hard disk structure:

The motherboard structure:

The optical drive structure:

And now an overview with (almost) all the assembled components, and some details:

And finally the two steel bars in which I will mount the PSU cover (these pics are taken before the third attempt to bend the PSU cover, so in that moment I didn’t have yet the final cover to mount in the case):

making and bending the psu cover

Now I’m starting a simple psu cover, that will keep in place the mysterious device too.

It should be a simple work, but I have broken two covers during the process, and I was able to complete it only at the third try!

The first was in polycarbonate, but I have broken it trying to bend it (same problem of the motherboard structure).
Here I’m cutting and polishing the panel:

And this is the first attempt to bend the panel, first with a wood cutting board:

and then with the steel base of the case 😀

…but trying to bend it I have broken it, so I had to restart the work.

At this point, I was hating the polycarbonate, so for the second attempt I tried to use a plexiglas panel, to bend it easily with heat.

Here I cut and polish the plexiglas panel:

and then I bent the panel heating it with a gas torch. This time the bending has been very very easy!

This is the bent panel:

The bending was good, and the plexiglass seemed perfect for this kind of work, but then I have broken it in a stupid way!
I had to make two holes in the panel, to mount it on two joints, but I broke the panel drilling it! I discovered that the plexiglas is a lot more fragile than the polycarbonate!
And the worst part was that even if I remade another plaxiglas panel, for that mounting type I could not use it, because it could broke in any moment… (this cover must be resistant to flexing, because it is mounted on only two joints, so the polycarbonate was the best material for this purpose).

The first two failed attempts:

And this is the third panel (in polycarbonate!) ready to been bent:

To bend it, I tried the same method used for the motherboard structure (putting the panel in the wood planer), but this attempt was failed:

Then I had another idea: wrap a long wood board to the vice, to make a huge lever on the panel right on point to bend, going full-weight on the other side of the lever:

with this method I was able to achieve the two desired bendings on the panel:

…and finally this is the result!