PROJECT: HTPC-3 Part 3

Here we go with part three and this is up to date. Hopefully now it will be semi real-time.

Above are a few pics of the box with some wood filler applied. As I mentioned, I wasn't able to make clean cuts, part my lack of ability, part table saw failure. Anyways, I hate to waste stuff, so I've decided to save this project with liberal amounts of wood filler and as we will see, sawdust and wood glue.

Semi-closeup of the top plate mount with the 80mm fan intake below it.

Wood filler ahoy!... on the sides.

From the front again, I think I am going to fill in those holes meant for buttons. For one, they are tottally misaligned, and for two, I'm thinking of mounting the buttons on the side or in back.

So here is where the sawdust and woodglue comes into play. The top plate was cut badly askew on both sides. Today I had a spark of inspiration, since I ran out of wood filler and couldn't be bothered to buy more...plus it kinda sucks for this type of an application. Heralding back to the days I aspired to be a surfer, and after watching my older brother, i remembered how I (and he'd) fix gouges, dings and cracks on surfboards. Duct tape and resin. Duct tape to hold a form and then drop the resin in and let sit. After it dries, peal the tape off and start sanding.

So that's pretty much what I did. I taped around one of the sides and then filled the form with my concoction. Then let bake in my server room/closet overnight. Hopefully this works. And if it does, I get to do the other side tomorrow.

A few shots of the box post, preliminary sanding.

The box posing with the Gorilla Glue Tape. Hardcore stuff.

The Ingredients.

So far, I'm happy with the results. I wish I the PSU mounting holes turned out better, as well as the HD cage mounts. I had to cut the MB standoffs down as they were too tall and impeded the MB from being lifted off of the box, due to the Audio jacks sticking out too far in the back and catching on the rear panel as I lifted the MB off. If the sawdust glue pans out, I'll probably apply it in other places and hopefully be able to paint next week. I'm going to run out if time tomorrow probably so it may be post-poned until sometime next week or after.