Ok I was inspired by Johnny English's fancy psu he uses for testing. I just recently aquired one myself and wanted to do something to it! I've seen where you can buy replacement lids for your psu's, but seeing as how the psu I have is somewhat old, I doubt this will work. I thought about making the entire closure out of plexi, but had a few questions. First how the heck would I ground this puppy? I notice the ground wire from the inside of the plug screws directly into the psu case. Am I correct in assuming that because Johnny English's psu is not actually installed into a case that the ground on his psu serves no purpose? Second, anyone know where a good how to exists on how to bend plexi? I am hoping to shape the two pieces of plexi just like my psu, so I would need it to be pretty accurate for the two pieces to fit together well.

In theory you could shape plexi but heating it then forming it.....although it may discolor if you heat it to much. Perhaps try a heat gun, then bend as needed.......

Quote: Originally Posted by RAA_Kr1cH Ok I was inspired by Johnny English's fancy psu he uses for testing. I just recently aquired one myself and wanted to do something to it! I've seen where you can buy replacement lids for your psu's, but seeing as how the psu I have is somewhat old, I doubt this will work. I thought about making the entire closure out of plexi, but had a few questions. First how the heck would I ground this puppy? I notice the ground wire from the inside of the plug screws directly into the psu case. Am I correct in assuming that because Johnny English's psu is not actually installed into a case that the ground on his psu serves no purpose? Second, anyone know where a good how to exists on how to bend plexi? I am hoping to shape the two pieces of plexi just like my psu, so I would need it to be pretty accurate for the two pieces to fit together well.

I wouldn't describe my desk/test PSUs as fancy - one is a Chieftec unit I didn't want to trust full time in a rig full time after one of the caps overheated, the second is a unbranded, underpowered unit that was surplus to requirements. In both cases, the mods performed were modest - shortened/modified output loom, handles, a quick spray, & LED fans.

Grounding - in "normal" circumstances, the earth wire fixed to the psu case does nothing; it's only when you get something abnormal happing (static buildup, or the psu case getting energised due to a serious internal fault) that it shunts any voltage away; In my desk/test psus excatly the same is true.
Of course, when a metal psu is in a metal case, the same protection the earth connection gives you is also extended to cover the case & any other components inside it....

What I'd suggest is that you drill a hole in your PC case & your plexi psu case & fit a nut & bolt to both (make sure you insulate the outside portion of the bolt on the plexi), connect the earth from the power socket on the psu to the bolt in the psu, then run a wire from the psu bolt to the case bolt. That way you get the benefit of protection from any electrical mishaps in the case, and can dissipate any static buildup on the plexi too.

As for building with plexi, I'm not aware of any how-tos out there ... I think you're going to have to experiment - if you're not sure where to start, I'd suggest making a framework in square section plexi rod first, then doing one U-section at a time. Prototype it in card first, then cut strips the rigt width, & use a hot air gun to soften the plexi before bending it around a suitable former (like a big block of hardwood with a lightly sanded bevelled edge to it). Once you've done one bit, your card prototype for the other U-section will be a lot more accurate.

Another option you might want to think about is to keep the back portion (& bit the PCB is screwed to) of the existing psu case, make a frame work out of plexi rod, & screw flat panels to that. It's less ambitious, but it might help you work out some of the difficulties so you can do your full plexi mod next time.

Either way, make sure you take copious notes & lots of photos - if it works out well it's the sort of thing that should go on PRs front page

Quote: Originally Posted by RAA_Kr1cH Second, anyone know where a good how to exists on how to bend plexi? I am hoping to shape the two pieces of plexi just like my psu, so I would need it to be pretty accurate for the two pieces to fit together well.

This should help.

Quote: Originally Posted by unholy This should help.

Good find unholy

Thanks for the help! I guess its time to go get a heat gun.

Well I decided to just cut the plexi instead of using a heat gun. I didn't think that I could achieve the tollerances that I wanted with bending. I took the dimensions of the psu and cut the plexi to size.
Again so you can see what I am working with, heres a pic of psu I am using.


I took apart the psu and cut off the two mobo connectors, then applied hot glue to the cut wires.

I cut the plexi using my table saw, but because its a crappy saw it left some tool marks. I figured that I would clamp all the pieces together and use my random orbit sander to clean the edges up.



Unfortunately it didn't leave the edges flat so I ditched the power tool and got out the wet sand paper.


I have never wet sanded before, and was not really looking forward to it. I do some wood working and sanding sucks big time. I was surprised how easy it was, and dare I say I actually enjoyed it! It took me a couple hours to clean up all the edges and fix the mistakes I made earlier with the sander.
I taped the pieces together to show you about how it will look.


I plan on gluing the pieces together using Weld-on #3(if I can find some) into two "U" shaped pieces. I will tap the plastic on top and bottom for some #6 x 32 flat head machine screws to hold the two pieces together.

I plan on using the original metal case as a template for cutting the holes for the fan and intake on my r...outer table.

Here some hardware I hope to add to this thing to bring up the bling factor.

I'll shorten up the power cable and install one of these.



Add these guys to the bottom


And replace the black case fan with one of these.

Looking good so far Crunch

I'm not convinced that even that fairly chucky plexi is going to take the weight without some internal bracing ... what case is it going into? If it's one with rails running from front to back under the psu I think it'd be worth making some spacers to provide direct support ... otherwise I can imagine it being fine for a while, then it'll go "crack!" & spew bits everywhere

Its not going to be in a case, I plan on just using it as a test psu.

Ordered the fan and the switch today. I was hoping to not have all the wires hanging out of the end of the psu, I thought about just shortening up the plugs, but if I had something like the plug setup in one of the x-connect psu's that would be sweet! I did some searching and couldn't find anything.

EDIT: worked on the back panel a little bit. After about an hour of screwing up I finally got something I am happy with.


I used an 1/8" bit in my router table and cut those slots to aid in cooling. The power button will be mounted somewhere at the top of this piece. Hopefully I will be able to install some kind of plugs like in an x-connect instead of just a hole with wires sticking out.