Cut out and dry fit a piece of aluminum for the Aux box I/O panel.
I decided to go with the minimum...power switch, power jack and audio out. Not much more room for anything else.
Dry fit the panel. This will be framed up to hold in place.
The DE box gets put together after cutting and gluing up pieces.
I mitered both ends of the the wood pieces to allow me to match up the best ends. Not all miters are the same even using a precision tool.
After cutting and trimming.
Roughly arranged boxes.
Cut three 8" x 3" pieces of cherry veneer.
Glued and clamped things up.
After nine hours of drying time (three hours each piece) I trimmed up a few of the edges.
Sanded with 100-grit sandpaper and hit it with a coat of lacquer sanding sealer.
Working on the SSD box rabbit hole.
The hole is restricted in size by the location of the optical drive located immediately on the other side of the board.
The angled SATA cables come out at 90 degrees and immediately have to turn under and go through the rabbit hole. This presented a problem with the data cable because it is not so flexible.
I devised a spacer to raise the SSD a 1/4" so that the cable radius wasn't so tight during the turn under.
The additional spacer also opens up the passageway for improved airflow. I'm not sure exactly how much heat an SSD actually generates but I think this cooling setup will do. They are designed to be used in a cramped laptop space with little (if any?) cooling so we'll have to see.
I marked out the approximate location of the SSD box rabbit hole.
Used my small (25mm) hole saw and hand rasp to open up the hole most of the way. This is 5-ply birch plywood with an additional ply of Hard Pennsylvania Cherry so it is much slower going than working with basswood.
Set up this fence to assist in getting the position accurate and help prevent creeping duriing the gluing process.
Same process with the much larger Pico box rabbit hole. I also finished opening up the SSD hole and smoothed out the passageway edges.
I realized about this time that I should have done some finish work prior to gluing anything on because the support box surface was only going to get more inaccessible by adding "obstacles". I sanded the surface with 220-grit sandpaper and applied a couple of coats of my brush-on satin-finish lacquer.
Mmmm. Shiny...but not too shiny. This is my clamping scheme for the Pico mounting board.
Finished opening up the holes and dressing them up with files/sandpaper.
Everything seems to be tight and square. I'll finish the tops of the boxes much later.
Testing my friction fit boxes. This is how I measure the accuracy of my work. The goal is to be able to easily remove and attach the boxes while still maintaining a tight friction fit.
The Aux box work has been challenging and I have presented a condensed version of the work in the following photos. A great deal of thought and anxiety has been expended in its construction and design. What is missing is the lengths I went to ensure proper positioning and alignment.
Anyone who has built a scratch-built computer case can tell you that designing maintenance access is very challenging. When working at this small scale those challenges can be even greater. It is much easier to build and make something look good if you have no concern for having to tear it apart a year from now to fix or upgrade the equipment contained within.
Blah, blah. blah. On with it...
Marked up and cut out the hole for the exhaust fan. Crazy, almost impossibly tight fit is required here.
Installed the fan into the aux box mounting board.
Dry fit the aux box mounting board. In this photo I have included the case's back plate. Unlike the Level 10 case my design will have a permanently fixed back plate.
Countersunk screws are used to attach the "cooling fins" to the mounting board. The mounting board will be painted flat black and the fins will be aluminum. The protruding edges inside the fan hole will later be trimmed and rounded to help with fan air flow.
I had to shim the mounting board to make up for the thickness of veneer yet to be applied to the surrounding Pico and SSD boxes. This will ensure that all the boxes will extend out to the same height.
Trimmed up the shim, drilled out a hole for the wiring, trimmed up the fan hole obstructions and screwed everything back together.
Completed aux box except for wiring and paint. Two AA batteries auditioning for size comparator.
When assembled, the fan extends into the support box space.
Additional wood pieces are framed around the fan and glued firmly up against the fan body. In this photo I show the position of the optical drive and the proximity of its adapter to the Pico box access.
Cut out a block to use as the mounting board for the DE box. Rep for guessing what DE stands for. The DE box has a single coat of aluminum paint, first of many more to come.
This is the rig I built to help me sand wood edges down to an exact size. One fence pinches down 60-grit sandpaper and the other fence is "hinged" to give me control. Back-and-forth, flipping it around to even out the process. Shift the sandpaper often to refresh it. Constantly test fitting the piece to judge progress and make adjustments.
Success. This block isn't coming out of its hole...not yet anyway.
I like to use blocks of wood or combinations of different blocks to get the spacing I like. These two boards are what I used to space the Pico and SSD boxes and I'll be using them again here.
Another spacer is set up to ensure conformity with the bottom of the Pico box.
Set the DE box in place.
Flipped it over, drilled pilot holes and fastened the box with tiny brass wood screws.
Now I can flip it back over and pry the DE box off its mounting board. I run a pencil mark around the perimeter of the mounting board.
Remove the screws from the back and using sandpaper I remove the lacquer finish to get back down to bare wood. Stay within the lines. I knew all that coloring book training would be valuable one day. Apply wood glue, re-install the brass wood screws and set aside to dry. After drying I remove the screws permanently.
Screws have a way of working themselves out over time and the surface behind the DE box is the optical drive casing. Besides, an wise old woodworker once told me that screws are used for things you plan to remove one day.
I thought it was a good time for a test fitting. Note the USB ports above the optical drive.
Painting and wiring...go.
To start the wiring process I mount the motherboard and ALL the onboard connectors to check for clearances and to see if the box still closes over the top of it. I was concerned about the IDE cable and the height of the SATA cable.
The only issue I uncovered was the front USB cable.
I had to peel back the USB cable's factory heat shrink to get more flexibility in the cable end. That worked.
After a couple of coats of aluminum paint it was time to try to remove it all. I used my sanding block to hand mill the edges down until all the paint was gone and all the edges were flat and even.
After about twelve coats of paint.
Handbrushed the interiors with a machinery gray flat latex paint.
Still more flat gray (and much more to come). That paint looks the same as what I used to paint my deck this weekend. Huh? Imagine that...
Back panel interior leaving the glue-down surfaces raw.
Top-side. I didn't paint the vertical box mating surfaces...yet.
Other half of the interior. The white dots are velcro that I'm using to temporarily secure the optical drive and USB ports while I'm wiring them up.
Everything connected and routed around. A little "lost art" IDE cable origami was performed. Whether the onboard power supply would power the optical drive through the 44-pin IDE cable was the big question. It appears to work fine. I'm still having a hard time believing that the Pico contains its own PSU.
The assembled and installed auxiliary box with new power switch.
Cut a rough outline out of aluminum sheet with my Dremel and finished off the edges with a metal file. I made the width of the piece the same as my 6" straightedge that way I could use it as a guide for my filing effort.
Semi-finished piece. The far edge is still rough because it will be cut off eventually. I use it to clamp the piece down without fear of scratching anything important.
Meanwhile, I've glued up the back panel veneer. The dark edges are the result of sunlight hitting the stored veneer sheets. Cherry, like mahogany, is very photo-reactive so I am currently "baking" the panel in the sun to even out the tone. Hopefully this and some deep sanding will help hide the seams.
I cut out some cherry veneer to surround the aluminum bits. A midsection was cut out of the large aluminum piece. I felt that creating two sections from a complete piece would help with the continuity. It just seemed like the right way to do it.
Dry fitting. Keep in mind that I have an "overhang" of veneer all around so the boxes appear larger than normal.
This solution solves the cherry-on-cherry seam issue and gives me the connected flow illusion I'm looking for.