[Build Log] Stalker v2.0 - Custom Micro PC build [Complete]

[MEC-777]

This is the next evolutionary stage of a custom build I did earlier this year; Project Stalker, which you can find the original build log for here: http://linustechtips.com/main/topic/365996-build-log-project-stalker-complete/ and my first dive into major custom case modding/building.

 

Been thinking about what to do as my next project and thinking I'd love to try doing some more "heavy" case modding. Was sitting around one day a couple weeks ago, looking at Project Stalker with the side panel off thinking of what could be done to improve this PC. One thing that struck me the most was that there was a considerable amount of wasted open space inside. One of the main functions of Stalker was for it to be a portable PC - easy to carry around. Well, making it much smaller would make it a lot more portable. After spending some time messing around with a tape measure and moving things around, came up with a plan to remove 4.5" from the height and 4" off the depth. The result would be a very small PC 10" tall x 10.5" deep x 6.5" wide.

 

Just a reminder of what this PC actually started out as: 

 

 

Which was then gutted, pained and transformed into this:

 

 

 

Specs have changed a little since the original Stalker was completed and are now as follows:

 

CPU - Pentium G2358 @ 3.8

Motherboard - Gigabyte GA-H87N Wifi mITX

Memory - AData XPG 2x4GB 1600

Storage - Hitatchi 400GB 7200 HDD AData SP600 128GB SSD

GPU - Asus GTX 460 1GB GDDR5 DCU-Top (brand spanking new)

PSU - Cooler Master V650 Gold Semi-Modular

 

Just a few quick tags: @mr.squishy @tmcclelland455 @dragoon20005 @AlwaysFSX @Antibull

 

Now, I could have just taken a hack saw, made some marks and started cutting. But this wasn't going to be that simple to pull off. I had to think about how the top, sides, bottom and front/back ends would all "fit together" after cutting sections out. Also had to think about how each section would be fastened to one another. Eventually figured it out (for the most part) and started taping off where to make all the cuts. I wanted to keep the clean face panel which means that has to be cut down as well. Turns out the section with the two 5.25 bay doors and the weird HP drive bay section, could be cut out completely and the rest will line up almost perfectly (at least in theory... lol, we shall see.).

 

 

 

 

 

There are a lot of rivets to be drilled out and precision cuts to be made. Thus, the tools of the trade. Went through about 10 of those little cut-off discs and they aren't cheap, unfortunately. But they are perfect for making thin, straight, controlled cuts in sheet metal.

 

More updates and pics to come soon.... 

 

Thanks for looking. Any tips/suggestions for doing this type of case modding is welcome.  

[AlwaysFSX]

Deathwheel? Good modding then!

[TheKDub]

Good luck!

[flibberdipper]

Damn you for using an image service that my school blocked.

[MEC-777]

Damn you for using an image service that my school blocked.

 

lol, sorry man. I would have used imgur but I don't like their album management (or lack there of).

[arnavvr]

lol, sorry man. I would have used imgur but I don't like their album management (or lack there of).

 

Why u no tag me?

[MEC-777]

Why u no tag me?

 

Didn't know I was supposed to... Assuming you followed the first build?

[arnavvr]

Didn't know I was supposed to... Assuming you followed the first build?

 

I did.

[MEC-777]

I did.

 

Ah ok. I was going to tag everyone that followed the first build, but I didn't want to force members I don't know very well to look at the new build, that's all.

 

But I will be posting a link to this build in the old thread for those that want to keep following. 

[arnavvr]

Ah ok. I was going to tag everyone that followed the first build, but I didn't want to force members I don't know very well to look at the new build, that's all.

 

But I will be posting a link to this build in the old thread for those that want to keep following. 

 

Ye, I found out about this through Show off your setup. What is the use for this PC?

[MEC-777]

Ye, I found out about this through Show off your setup. What is the use for this PC?

 

It's a portable Linux gaming rig, mainly. Took it to a friend's house a couple months ago which is when I realized it was still too big and not as portable as it could/should be.  

[flibberdipper]

lol, sorry man. I would have used imgur but I don't like their album management (or lack there of).

Imgur is blocked too.

[mr.squishy]

Subbed

[MEC-777]

Imgur is blocked too.

 

Well then, I guess you're sol until you get home.

[MEC-777]

And so the cutting commenced... Slicing down the case actually went pretty smooth. Took my time to double and triple check every cut to make sure it was right. Nothing worse than cutting in the wrong spot.

 

The first cut:

 

Hard to get each cut perfectly straight. Just went slow and steady. Really helps to use the tape as a guide. Can see here how much is being trimmed off and how much smaller it will be when it's done.

 

 

After some time cutting, was left with what you see here. At which point my wife said, "Why did you wreck your computer?", to which I simply lol'd

 

The new shortened front panel, which will be covered up:

 

More pics on the way...

[MEC-777]

First mock up of the new assembly. Pieces fit together well, surprisingly. Still need to do some trimming and grinding to get the fitment just right, but it's nearly there. Will probably use mostly rivets to fasten the new panels together and 2-part epoxy where rivets can't be used. 

 

 

 

 

Can see here how tall it used to be with the original front cover (which I still have to cut down). 

 

Gives some perspective next to the uncut removable side panel. Still have to figure out exactly how to cut that panel down as I want to still be able to remove it easily. Toying with the idea of using hinges and maybe have it swing open like a car door...

 

And finally, threw some of the hardware back in to see how everything looks and fits. Damn is it small. lol. PSU will mount above the motherboard like in the Elite 110, as you will see in a moment. Haven't figured out yet where to mount the HDD or if I'll even be putting it back in. SSDs are so cheap now, might just grab a 128GB and tuck it up inside somewhere. Air flow shouldn't be a problem with the 120mm intake fan on the front and the handle hole in the top for the graphics card to breathe. The PSU will pull it's own supply of air though vents in the side panel and exhaust out the back.

 

 

Only 10" x 10.5" x 6.5". Smaller than than my old Node 304, as you'll see in a moment, and yet this can also take an mATX motherboard.

 

The tape is just there to hold it together temporarily. 

 

Size comparison with the node 304. 

 

 

 

 

Better view of the hardware and PSU placement. Glad that PSU is semi-modular. Going to be fun sorting out the cable management. 

 

 

 

Next steps are to get the front cover cut and trimmed down, get the case panels trimmed and fitting properly. Then rivets and epoxy to 'seal the deal'. 

 

For the paint, I'm trying to decide what to do. Right now I'm thinking to keep it matte black like it was, but I have a few other ideas in mind and I'm also open to suggestions. Any thoughts on a theme or specific colour(s)?

 

Thanks for following so far. More to come soon.

[Guest]

Why not fan down for the PSU? it would give a little bit of exaust.

[Darkman]

First mock up of the new assembly. Pieces fit together well, surprisingly. Still need to do some trimming and grinding to get the fitment just right, but it's nearly there. Will probably use mostly rivets to fasten the new panels together and 2-part epoxy where rivets can't be used. 

 

Can see here how tall it used to be with the original front cover (which I still have to cut down). 

 

 

Gives some perspective next to the uncut removable side panel. Still have to figure out exactly how to cut that panel down as I want to still be able to remove it easily. Toying with the idea of using hinges and maybe have it swing open like a car door...

 

 

And finally, threw some of the hardware back in to see how everything looks and fits. Damn is it small. lol. PSU will mount above the motherboard like in the Elite 110, as you will see in a moment. Haven't figured out yet where to mount the HDD or if I'll even be putting it back in. SSDs are so cheap now, might just grab a 128GB and tuck it up inside somewhere. Air flow shouldn't be a problem with the 120mm intake fan on the front and the handle hole in the top for the graphics card to breathe. The PSU will pull it's own supply of air though vents in the side panel and exhaust out the back.

 

 

Only 10" x 10.5" x 6.5". Smaller than than my old Node 304, as you'll see in a moment, and yet this can also take an mATX motherboard.

 

 

The tape is just there to hold it together temporarily. 

 

 

Size comparison with the node 304. 

 

 

 

Better view of the hardware and PSU placement. Glad that PSU is semi-modular. Going to be fun sorting out the cable management. 

 

 

Next steps are to get the front cover cut and trimmed down, get the case panels trimmed and fitting properly. Then rivets and epoxy to 'seal the deal'. 

 

For the paint, I'm trying to decide what to do. Right now I'm thinking to keep it matte black like it was, but I have a few other ideas in mind and I'm also open to suggestions. Any thoughts on a theme or specific colour(s)?

 

Thanks for following so far. More to come soon.

This really makes me want to do something with a Dell Inspiron 570 case I have sitting around.

[TheKDub]

I'd suggest going for hinges for the side panels on it, though even better would be ones that when you swing the doors open, you can lift the door off, then just use some sort of ball catch mechanism for latching it.

 and 

[mr.squishy]

For the paint, I'm trying to decide what to do. Right now I'm thinking to keep it matte black like it was, but I have a few other ideas in mind and I'm also open to suggestions. Any thoughts on a theme or specific colour(s)?

I think you should replicate the metallic blue that your 460 is 

[MEC-777]

Why not fan down for the PSU? it would give a little bit of exhaust.

 

Thought about that, but I'd rather have the PSU pull it's own supply of air instead of fighting the CPU cooler for air. There's already vent holes in the side panel in just the right spot for it anyways.

 

I'd suggest going for hinges for the side panels on it, though even better would be ones that when you swing the doors open, you can lift the door off, then just use some sort of ball catch mechanism for latching it.

 and 

 

Great idea! Thanks. Will definitely give this some thought. 

 

I think you should replicate the metallic blue that your 460 is 

 

Was thinking about maybe doing a Fallout 4 theme and painting it a 50's orange and making it look old and rusted. The colour and style of that 460's shroud has that 50's style to it, so it would match well.  

 

Maybe something like this colour, only not so rusted looking. And if I used exposed hinges, it would still fit with the theme.

 

 

I don't know, I'm torn. I like clean, minimalistic black, but I also kinda like the idea of some kind of theme, as long as it's not over done... 

[flibberdipper]

Thought about that, but I'd rather have the PSU pull it's own supply of air instead of fighting the CPU cooler for air. There's already vent holes in the side panel in just the right spot for it anyways.

 

 

Great idea! Thanks. Will definitely give this some thought. 

 

 

Was thinking about maybe doing a Fallout 4 theme and painting it a 50's orange and making it look old and rusted. The colour and style of that 460's shroud has that 50's style to it, so it would match well.

 

Maybe something like this colour, only not so rusted looking. And if I used exposed hinges, it would still fit with the theme.

 

 

 

I don't know, I'm torn. I like clean, minimalistic black, but I also kinda like the idea of some kind of theme, as long as it's not over done... 

Personally, I would paint it flat black and then wear it out a bit to make it look a bit beat up.

[mr.squishy]

Was thinking about maybe doing a Fallout 4 theme and painting it a 50's orange and making it look old and rusted. The colour and style of that 460's shroud has that 50's style to it, so it would match well.

 

Maybe something like this colour, only not so rusted looking. And if I used exposed hinges, it would still fit with the theme.

 

 

 

I don't know, I'm torn. I like clean, minimalistic black, but I also kinda like the idea of some kind of theme, as long as it's not over done... 

I love the idea of making it 50's style, but I dunno about pairing that blue with that orange.

[MEC-777]

If I do paint it black, might try to do the Stalker logo on the side. Maybe something like this:

 

 

(fixed broken image link)

[MEC-777]

Ok, big updates and lots of pics. Here we go...

 

Did a lot of extra trimming and fitting to get all the pieces and panels to fit together just right. Got the PSU mounted and test-fitted:

 

 

 

 

Tight fit between the PSU and stock Intel heat sink, about 5mm. 

 

Looks like the vent on the side panel will line up well enough. This system won't put much load on this PSU, so it'll be getting more than enough air. 

 

Got the front cover cut down to size and set it in place to see how it might look. 

 

 

Next up, the rivets. First two installed:

 

And then there were 5...

 

And the rest followed...

 

Once all the rivets were installed, the whole chassis is surprisingly solid. Next step was to install all the components and see if all the necessary cables would actually fit... And they do.

 

There it is, everything stuffed inside. When I do the final assembly I'll do a much better job with the cable routing, but this was just to see if it would all fit and run without any issues. 

 

 

 

Couple shots showing the new rivets. Whole chassis will be repainted, so don't worry about all the scuff and scratches.