Component Housings
As with any mod I do, I painted the component housings (CD-ROM, FDD, and a junction box) semi-gloss black. This gives it a nice, satin-like finish, without being dull or shiny. I masked off the plastic LED covers of the floppy faceplate, and didn't bother painting the CD-ROM faceplate since it was already black. I did have to later apply some hand glaze to the CD-ROM faceplate to polish a little "wet look" into it to match everything else. For now, here are the painted covers and faceplates:
EL Lights
Since I strongly feel that CCFLs and clear acrylic cases are poor combinations, I'm opting to go with a little bit of EL lighting for highlights. It's a subtle glow around just the light strip/wire itself that adds a nice touch to clear cases. Of course my other alternative is to go UV with UV CCFLs, but I'm really bored with the whole UV craze. I'd much rather have something that looks like it came from the movie "Tron" than something out of a really bad Rave party.
The kit itself, both powered off and on:
Since the inverter for the EL lights emits a high-pitch whine, I decided the encase it inside my own enclosure. The whine seems to be curtailed when the bottom of the unit is sealed by a dense mat or rubber, along with some weight or pressure on the top to keep it sealed. Therefore, I put both molding tape and part of a rubber mouse pad under it, then stuffed it into an enclosure with foam to reduce the shrill sound leakage. I didn't want to use a clear enclosure here since the use of all the foam.
Voltage Conversion
For such a simple issue, this is by far one of the greatest portion and challenge of this project. The problem: many high-end, modular power supplies do no supply a -5V wire (white) to the motherboard, meaning they are unable to generate -5V at all. It isn't needed for newer motherboards, because only the old ISA bus (its controller) utilizes -5V. Some mid to low-end power supplies still offer this -5V output, but I have my mind set on an Enermax, SeaSonic, or PC Power & Cooling. I purchased an Enermax Liberty 400W for this project because of both its good build quality and its use of modular cables. Although I will be cutting and splicing cables as I see fit, I still enjoy the modular output design.
To accommodate my choice, I need to design and implement a separate device to output -5V to the motherboard. After some research, I discovered that an electronic component known as a 7905 voltage regulator will take in -12V (already supplied by a PSU) and output -5V. The only problem is, this is a PC board mount style component with connections that should be soldered. To make it worse, the voltage regulator itself is not enough for reliable operation. It needs capacitors on both its input (-12V) and output (-5V). And if that couldn't get any worse, I was never good at soldering and ditched the notion of it many years ago.
Fortunately, with the help of the community members at
Electronics Forum, plenty of online research, electrical design software (
KiCad), and many purchases at my local Radio Shack store, I was able to fabricate this voltage conversion unit, and even make it looks presentable in the process. Furthermore, I learned to embrace soldering and pick up hobby electronics.
I first double-checked the simple design in KiCad. It was complicated for me, being an electronics noob, so I wanted to make sure it looked right with those on
Electronics Forum first.
I then tested everything in a breadboard before actually soldering together components. Instead of my KiCad plans, I decided to go with 22µF capacitors on both the input and output to ensure stability.
I used a clear acrylic card holder box as the housing of the unit to keep in line with my case's clear theme. I drilled holes in the side for binding posts, and larger holes at the ends to help with ventilation.
Top (component side), bottom (soldering and wire side), finished with lid off, and finished with lid on:
Power Supply
The power supply is one of the last components I'll have completed. The -5v issue, conversion from ATX to Dell proprietary power connector, and even sleeving have delayed it. I found a great reference for
converting to/from Dell's proprietary power connector on someone's personal site. Here's what I've done so far with the Enermax Liberty 400W PSU for this build:
System Preview
Here's a quick shot of the front-panel pcb before I modded it. I ended up removing (desoldering) components, cutting down the height of it, and then painting it black as shown later. I did remove the front-panel audio and USB connectors before taking this image.
A couple shots of the partially-installed PC in the modded Sunbeam UFO case: