The ATI / AMD Shuttle PC by ZapWizard

[ZapWizard]

Hello folks, some of you may be familiar with my previous modding projects.
If not visit: http://www.ZapWizard.com

This project is going to be a showcase for the ATI Radeon Graphics cards, and the AMD Athlon64

The PC will travel with ATI to different shows and events to show off the products inside.

This thread will be an cut-and-paste copy of my project log at Bit-Tech:
http://forums.bit-tech.net/showthread.php?t=55296

Now onto the project:

[ZapWizard]

The ATI / AMD 64-Bit Shuttle PC

The Plans

Click for a larger image


This will be a mean looking and super fast 64-bit Shuttle PC.

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Now for a taste of the mods to come:
(Images made in trueSpace3)


The left side will have a tinted window featuring the graphics card.
The window and card will be using orange, amber, and red LEDs to create a flaming effect inside the PC and graphics card.

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The right side will have a window with the "ATI Get in the GAME" Logo.
This will be backlit using white LEDs
I may have more flame effect at the bottom of the window.

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The top will have a AMD Athlon 64 Logo, backlit using white LEDs
Plus an actual Athlon 64 chip, with deep green lighting coming out from behind the pins.
The extra Athlon64 at the top will be just for looks, and is already a non-functioning part that I have.

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The front will have the most customizations.
First, a custom black painted alluminum plate backing, with a plexi glass cover.
The saw blade will be custom cut, and in-set into the plexi.
In the middle will be the bulgin switch, with LEDs for harddrive and network flanking the sides.
The Bulgin switch will flash off in sync with DVD disk activity.
The single Bulgin switch will handle both DVD eject and system power.

The front will have 4 custom 7-pin jacks that will connect to the various USB perephrials.
(The extra pins are for expandability in customizing the perephrials)

[ZapWizard]

The Parts

AMD Athlon 64 3400+







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ATI Radeon 9800XT


ATI Radeon 9800XT 256MB built by ASUS

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Shuttle SN85G4L Shuttle PC



The external dimensions are (L)295mm x (W)200mm x (H)180mm

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1GB of Corsair XMS Cas2 PC3200 400Mhz DDR



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36GB Western Digital Raptor SATA Harddrive



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Pioneer 120S Slot load DVD Drive

[ZapWizard]

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Logitech Stereo USB Headset 200



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Logitech Elite USB Keyboard



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Logitech MX510 Performance Optical mouse



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Pre-Modded parts:
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Red Anodized Aluminum Thumbscrews



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Red Anodized Thermaltake Memory Cooling


(On back-order)

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Red Anodized Thermaltake Tiger1 Chipset Cooler


(On back-order)
The fan will not be used.
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Red Anodized Aluminum 80mm Chome Fan



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Red Anodized Aluminum 60mm Chome Fan



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Bulgin Red Vandal Resistant Illuminated Ring Switch

[ZapWizard]

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PC Toys Flame Mouse Pad


(I already had this gaming pad lying around)

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Red Neon SATA Cable



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Other parts
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Cooler Master Copper RAM sinks
(For use on shuttle motherboard parts)



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Custom 7-pin metal connectors



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[ZapWizard]

To keep things moving fast I will only be taking images once a modification is complete, rather then a step-by-step.

I have a guide for this mod here:
http://forums.bit-tech.net/showthread.php?t=23375

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The Pioneer DVD Model 120S

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Backlight day shot using clear CD
(The kind that come as a protector in a stack of CDRs)

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Daytime edge shot

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Night-time Edge Shot

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Night-shot

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The DVD will also directly run the Bulgin Switch.
The switch LED will turn off when the DVD is active, and remain on when the DVD is inactive.
The Bulgin switch will be the only switch on the front of the PC, and will be used for DVD eject.

The power and reset will be located on the back of the PC.

[ZapWizard]

ATI sent me the special edition ASUS built model of the Radeon 9800XT.
This is a 256MB card with two clear fans.
It also has video-in and a few special features.

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I used two Red LEDs and a single Orange LED (All 3mm size)
They create a beautiful flaming effect.

This image doesn't do it justice, as there is a gradient of color between the middle and edges of the fans.

I may not use Yellow LEDs at all in this mod, as they mix with red, and turn everything orange.

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The night shots show the true effect much better.

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This shot is of the card during burn-in on my main system.

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[ZapWizard]

Here is some more eye candy, and parts I hadn't photographed yet.

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The Bulgin switch lit up.

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The non-fucntional Athlon 64. This is actualy a mobile part as it does not have a heat spreader.
I have already tested with some green 3mm LEDs, and the effect I want under the pins will work great.

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The fasteners for the case windows and front panel.
I have come up with a few new ideas for the case windows.

Rather then cut in holes, I will offset the windows by 1/4" away from the side of the case.
This will allow air to flow into the case very easily.

The dome nuts will be on the inside.
The outside hex bolts will be secured into the case, attaching the windows.
The actual hex head will then be filled so that the bolts cannot be removed from the outside of the case, giving them an anti-theft property.

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Some furniture castors that I will use as case feet.
The thread will have to be cut down for the shuttle motherboard.

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Over 160 LEDs! :cooldude:
There are zero cold cathodes in the plans.

Why LEDs only? They allow for very consistant coloring, they don't generate heat, and I can design a more precise effect using them.

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Clear Lexan sheets for the case windows and faceplate.
1/4" Acrylic will be used also in a few places.

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The security circuit and key-lock.
I have 25% of the circuit on a proto-board. (The other 75% is just the same anyways)

[ZapWizard]

Here about some images of the prototyping for the Athlon 64 Show piece that will be in the top window:



Four of these 3mm LEDs are very bright.

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The effect that will come out from under the pins perfectly matches my plans.

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Also the "AMD Athlon 64" Logo will be lit up using LEDs of different colors.

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Here is the back of the CPU with some of the pins removed.
I removed them by twisting a flat headscrew driver between pins.

[ZapWizard]

This is a teaser of what I am working on next.
It is a 1:1 scale prototype laser cut out of 1/8" Lucite.

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Here is a teaser from my test-setup for the front panel lighting.

[ZapWizard]

Now for some AMD Green



I have completed the UFO glow effect for the PC.

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Under the case, and centered on the bottom is a 9cm acrylic puck that contains twelve ultrabright 5mm Green LEDs.

You can also see the case feet are now installed.

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This close-up shows the LEDs, resistors and the two existing holes on the case I will use for mounting.
(They are the screw holes for mounting a 4-point heatsink)
The holes are off-center but the puck is not.

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If you stick you head under the case and look, it's pretty bright.



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More images here:
http://www.ZapWizard.com/ATI/UFO

[ZapWizard]

The Logitech MX510 Firewheel





The acrylic wheel is laser cut, and lit by two red 3mm LEDs.

I actualy tried to make a wheel in the same sawblade fashion as the front, it looked good, but was too fragile for use as a wheel.

Credit goes out to Japala at http://www.metku.net for the firewheel mod.

[ZapWizard]

I decided the try and paint the keyboard red to make it ATI colors.
But once I started painting, I found a much more wicked look, by just painting the edges of the keyboard red, and the middle a dark black.
All that I used was light sprays of black vinyl dye, and red Krylon fusion.

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I also replaced the green LEDs with red LEDs.
(They are very bright, but aim straight up, so they don't really get in your eyes)

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Here is a close-up of the paint job.
It transistions from total red, to total black from the edge to the middle.

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Here you can see that the color matches the mouse very well.
I will clear coat the keyboard later to give it protection for the road.

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This show shows what they look like together on a desk.


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I applied clear-coat to the keyboard.
Now it has protection for the paint, and a glossy finish.
I used "American Tradition Ultra Clear Protective Acrylic Finish"
Note that many clear coat paints are acrylic, so don't use alcohol to clean them.

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Here is a closeup of the finish.
The camera amplifies it, but the texture is about the same as the underlying plastic.

BTW, I did think about making that scroll wheel into a firewheel also.
But the 1/4" acrylic I have is too thick.
I may attempt it later if time permits.

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I also painted and applied clearcoat to the headset.

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Now there is a complete set of matching peripherals for the computer.

[ZapWizard]

One update for the top-window on the case.

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Here is the acrylic piece that will be installed into the top.

It was made by painting and etching multiple times to create the four needed colors.

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At an angle you can see the etch from the back.

The edges of the etch are also 'punched' so that they catch light better.
This piece will be lit up by either Green, White, and Orange LEDs, or just by white LEDs.
I have attempted several versions with just LEDs
One was Japala style with mutiple layers of plexi, each lit a different color. (www.metku.net)
-Dibs out to Japala for the Firewheel mod also.-
The other idea was to use a single piece of plexi, lit with different colored LEDs.
But this piece has turned out the best for lighting.

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Here is the prototype for the faceplate.

It is three layers of 1/4" acrylic vinyl dyed black on the backside.
The blade is also acrylic, but will be metal in the final build.

The DVD drive passes through the first two layers, and sits behind the final layer.

It is a little more complicated then it looks, as behind the blade is the cut-outs for the 24 LEDs that will be installed.

I have also added a few changes, such as back-lighting the Shuttle and ZapWizard Text.
And also the ATI text will be changed to the offical logo.

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The right hand side of this case didn't fit the overall theme of the case, so I decided to do an etch.

I used a Radeon 9800 Wallpaper from the ATI website, and worked it into a beautiful etch.
The etch is on 1/8" lucite that was vinyl dyed on the backside then etched through.
The result is a 'scratch-board art' look to the etch that can be front, side, or back-lit.

The etch is attached to my template that I will be using to cut the windows into the metal case of the Shuttle PC.

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Here you can see the mirror-black look that the etch has, and also the use of the spacers to raise the window off the side of the case.
This will allow airflow into the case from the edges of the window.

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Here is an image of the backside. On this side the paint is flat-black.
You can also see the window shape that I will be cutting into the Shuttle's metal case.

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Here is the Shuttle PC's metal case preped for cutting out the windows.

One problem with cutting out the windows, was the existing airholes in the case. They would have created a messy area to cut into.

So what I did was to mask off, and fill the air-holes with JB Weld.
(The gray spots on the case)
The JB Weld will make a strong and good fill for the metal.

This also means that I will also be re-painting the entire outside of the Shuttle case.

I plan on using a high-luster black paint, and then speckling it with a hint of Red.
The entire case will then be clear-coated to protect it.

[ZapWizard]

It took quite a bit of cutting (and cutting wheels) to get three identical window cut-outs into the case.
Believe it or not, this my first ever case window I have done.

I will slit-cut some small black tubing to create an edge for the window.

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Due to the cuts, and JB Weld added to the case it needs to be re-painted.
Fotunently I have 6 practice pieces to try different types of paint on.
(3 windows, and 2 sides each)

The above image shows the black brushed alluminum finish that is currently on the case.
The black finish is an anodization, which means I can put primer directly over it without having to sand down to bare metal.

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The easiest way to paint the case is to use a high-luster black paint.
While a shiny black paint job looks great, to me, this is rather boring, and won't look custom at all.

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So I tried the same technique as the keyboard, painting the high-luster black, then painting the glossy red over it.
Even though both are very shiny, they end up looking like a flat finish

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The solution is tricky:
I had to use two hands and aim both paint sprays at the same spot, allowing them to mix as they hit the surface.
It will be pretty tough to keep a consistant mix over the entire case, but the result is a beautiful speckled mix of black and dark red, yet remains very shiny.

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Here is an image of the case windows test installed.
Note the top window doesn't have spacers to raise it up.
That is because I will be installing a blowhole into back of this window.
The airflow for the Shuttle ICE cooler will be reversed, and the fan installed on the outside of the case. (Mabye)

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This is the closest to complete image so far.
It is a lot of black, but once the lights begin to join the mix the PC will come alive.

[ZapWizard]

I have shealthed the PSU with black braiding.
I will be adding a grill to the fan later.

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Rather then use a piece of large braiding (which the PSU came with) I felt that splitting up the wires into sets of four creates a much cleaner look.

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I gave the power supply a glossy paint job with clear-coat

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I also designed and cut a fan grill for the PSU fan.
Again I used the mirror-black technique on the lucite.
Credit to Macroman for that great technique.

[ZapWizard]

After tons of different fan grill designs I came up with this one.
It is a cross between a turbine and a flame effect.
I also choose to omit the center of the grill.

Note: The fan grill design is Copyright 2004 by Joshua Driggs

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The fan grill looks great against the anodized alluminum fan.
I vinyl dyed the back of the plastic to provide a black-mirrored finish.

This fan will be mounted externaly on the back of the shuttle.

[Shapeshifter]

very nice

wish I had all that

[ZapWizard]

Originally posted by Shapeshifter
very nice

wish I had all that

Me too... as I am not keeping this PC, ATI gets it when it's done.

[snookums]

i h8 u
my e-penis is shrinking the more i see of your mods

you're making everyone else look like a ****ing amateur!!!




never stop

[parisioa]

damn

[Rippthrough]

Coming along nicely, not sure about the paint, seems a bit flat, like you said. Wish they gave me the bits to do something like this......

[IAmIronSam]

Very cool. Shuttles seem like they'd be alot of fun to mod, I'm just reluctant to cut mine open.

[ZapWizard]

Here are some updates of things in the works:

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I painted the DVD drive case black, as it will be visible from the top window.
Why not do a DVD window?
Because there is not much to see inside a slot-load drive:
http://www.zapwizard.com/mediapc/dvd...e/Top-View.jpg

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The case feet have been installed for a while, but they stuck up higher then the spacers for the motherboard.



So the screw and nut were cut down lower then the spacer.
Any pins on the motherboard in these areas were also cut short.

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I applied marker to the vent holes on the powersupply, and I also changed the screws to the hex type.
The stainless steel screws polish up very well.

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Here is the final image of the PSU

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The key-switch and security status LED are test installed.
The LED changed between red and green. (Locked and unlocked)

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In order to secure the rear USB ports I cut the +5volt trace running to the ports. Then two wires were soldered which will run to a switch inside the case. The switch can then allow the USB ports to be turned on or off.

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I decided that the empty PCI slot could use something.
So I made a simple ZapWizard.com piece that will sit inside.

[ZapWizard]

The top blow-hole has been installed.
I painted the area in the middle of the fan black to hide the fan label and white fan parts.

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Here is a view from the back of the case.

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The fan grill was cut out of the back of the case.

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The 80mm CPU fan will be installed externaly.

[Lunar Wolf]

[Hamidxa]

How much time does it take to do all of that? Is it worth it?

[ZapWizard]

Originally posted by Hamidxa
How much time does it take to do all of that? Is it worth it?

About 2 months of my spare time.
Yes, it is worth it when you are in a room with 2000 other "normal" PC's and yours stands out.
(not to mention this is a contracted project)

[Tyrion]

Originally posted by ZapWizard
About 2 months of my spare time.
Yes, it is worth it when you are in a room with 2000 other "normal" PC's and yours stands out.
(not to mention this is a contracted project)

How much were you paid for this?

[The_Riddla]

Originally posted by ZapWizard
About 2 months of my spare time.
Yes, it is worth it when you are in a room with 2000 other "normal" PC's and yours stands out.
(not to mention this is a contracted project)

so their paying for it?