Hi all,

I've lent my cam to a friend to test for part exchange so no pics yet, hence overly long descriptions...

Wanted to put a new system in an aluminium Samsonite briefcase (the ribbed ones that only ever carry bombs, cash or secrets ) but at £300 not really worth it! I'm installing it in an old camcorder case instead, I know this isn't revolutionary but it's for work so it's a practical and pro looking mobile solution.

It's panels are plywood covered in a diamond textured metalic grey plastic on the outer skin and the framework is aluminium. Its quite sturdy but very light. Overall internal dims are 445mm x 310mm x 160mm. It's only a little larger than my calculations for fabricating a case from scratch. The panels just slot into the frame pieces then the frame is stapled (!) into the plastic corner brackets. May replace staples with self tappers.

Three main options:
1) leave it as it is (quickest. metalic paint?)
2) replace plastic skin with 'cornrow' aluminium (smartest, strongest)
3) ditch the plywood completely and just use the Aluminium (best heat solution but more vibration and weaker?)

Hmmm, I'm prefering number 2 so far... strength is a consideration with mobility, unfortunately all the hinges, handles and clasps are riveted in. Easy to drill out but a pita to replace.

I've also not quite decided yet whether to cut into the case for slots, leads, dvds or have just one grometed hole for leads. The latter means opening the case to wire it up and limits the length of usb devices like memory sticks but it makes it rain proof during carriage (handy in the UK). Probably have to cut holes though, could always make a nylon cover for it...

Ideas and Questions:

1) Cooling is an obvious issue with less conductive materials but it's not cramped in there so I'm sure good through flow will be easy. I'm planning a passive vent over PCI slots and a duct to the CPU, plenty of negative pressure will be created by 120mm PSU exhaust plus one extra 92 or 120 exhaust. Dust filtering isn't an issue 'cos it'll be open so often that quick blow outs will be frequent.

2) Static buildup on isolated metalic parts. I made this one up, is it likely to happen or be a problem?

3) Rubber or silicon mountings or washers on EVERYTHING for shock resistance, possibly a lot of silicon tubing cradles and straps. Do any parts need to earth to the case other than through cables?

4) May need to glue a few brackets into place 'cos I dont want to spoil the outer panels with rivets or screw heads. I know epoxy is used alot but its kind of brittle, anything better for wood to steel bonding? How sticky is silicon, i may use it to mount lighter bits like the fan?

Any answers and further ideas appreciated...

ps. I am willing to argue about the spelling of Aluminium!

al·u·min·i·um
n. Chiefly British

Variant of aluminum.

Ok, you get that one, yankee.

Sounds like a cool idea. It's been done before, but it always seems to tax the crapola out of the imagination. If you want aluminum for the case, I'd just save up and buy the aluminum case instead of buying plywood and re-inventing the wheel.

I wouldn't be too concerned with static as long as you have everything grounded properly.

As far as your leads and connections, I'd cut a slot in the aluminum case that would accomodate the I/O panel for your mobo.

For mounting, I'm sure there are tons of options for gluing and the like, but I wouldn't try to rely solely on glue or epoxies. I'd lean more towards at least a few, stylish bolts or anodized rivets.

The plywood is already there, it's just got a skin of plastic on the outside. I was suggesting replacing only the skin with aluminium because it only needs to be a very thin aesthetic layer, much cheaper @ £20 than buying a £300 samsonite case. Let's call it 'recycling the wheel'. I'm hoping for some amount of damping from the plywood too...

Buying thicker Alum to fit the frame slots and increase rigidity is probably out of my budget...

So it's narrowed down to either
a) leaving it as it is
b) replacing the skin with Alum.
This probably depends on how annoying the goopy yellow glue holding the panels in is.

As for the slots, you're right, I was kind of talking myself into it wasnt I, internal connectors would be such a pita. So slots and connectors cut into the case it is.

What is "grounded properly"? Are all components grounded through respective power cables? I'm assuming so, being a mechanical rather than electrical engineer... Otherwise do I just need to run an earth wire from the Alum frame elements to the PSU body?

Gluewise I guessed as much, just hoping for a magic sollution. Rivets would look better on the Alum than on the plastic....

Thanks for making me think more.

Hmmm...

Quote: Originally Posted by defunct The plywood is already there, it's just got a skin of plastic on the outside. I was suggesting replacing only the skin with aluminium because it only needs to be a very thin aesthetic layer, much cheaper @ £20 than buying a £300 samsonite case. Let's call it 'recycling the wheel'. I'm hoping for some amount of damping from the plywood too... Buying thicker Alum to fit the frame slots and increase rigidity is probably out of my budget... So it's narrowed down to either a) leaving it as it is b) replacing the skin with Alum. This probably depends on how annoying the goopy yellow glue holding the panels in is. As for the slots, you're right, I was kind of talking myself into it wasnt I, internal connectors would be such a pita. So slots and connectors cut into the case it is. What is "grounded properly"? Are all components grounded through respective power cables? I'm assuming so, being a mechanical rather than electrical engineer... Otherwise do I just need to run an earth wire from the Alum frame elements to the PSU body? Gluewise I guessed as much, just hoping for a magic sollution. Rivets would look better on the Alum than on the plastic.... Thanks for making me think more. Hmmm...

Yes, everything should be grounded just fine. Just make sure the mobo is floated, and not in contact with anything but its own mounts.

If you're just going to recover the plywood with aluminum sheets, why not countersink the bolts/rivets you use in the plywood, THEN cover everything up?

Shop around. I was at Boston Store (department store here) one time and they had aluminum samsonite briefcases for $45. I'f id had the cash i woulda bought one.

Quote: Originally Posted by Cyno01 Shop around. I was at Boston Store (department store here) one time and they had aluminum samsonite briefcases for $45. I'f id had the cash i woulda bought one.

It's not Samsonite, but Llamma has an aluminum briefcase for $35. Don't know how much shipping is.

Quote: Originally Posted by FunkyFresh It's not Samsonite, but Llamma has an aluminum briefcase for $35. Don't know how much shipping is.

Dang it! If only I could squeeze my CRT in there...heheheh

You can get that type of thing on eBay very cheaply.

Example: http://cgi.ebay.co.uk/ws/eBayISAPI.d...74548&tc=photo

dude, Home depot has 'em for $20. Also in black. I say don't cut a hole for the I/O panel. I got a case like that and regretted cutting the I/O shield into it. It looks ok, but a wireless nic, keyboard, and mouse will leave you with power and video to run. It can fit a 17" or maybe a 19" monitor, so if I could get a UPS to fit in there, it would be on. Of course I also need a new case cuz I hacked that hole in it. Now if I only had $300 to finish the project!

Really got to get my camera back, you're all pointing out the case I already have, pretty much, except for the plastic skin instead of Alum. Mine just has 1inch radius corners which gives it a neater look. Not so industrial.

FYI they've got nothing to do with the Samsonite cases I'm on about, go and watch Ronin or a couple of Bond films, one will crop up sooner or later. Samsonite ones are made of single sheets of formed aluminium not fabricated. Sweet smooth lines...

Anyhow, if I can pick one of these one up cheap in UK, with right dimensions, I'll do it.
If not I'll use HP07s suggestion of countering under the skin, thanks, why me no think o that...

I'll be sticking with a quality 15" Iiyama monitor in the case, partly for weight and space, partly for cost/ quality.

Probably still cutting holes in the case cos turning up to a corporate conference and fiddling in a box of wires don't look too professional AND still need nuff space for memory sticks to swap files on site.

thanks for it all...

Quote: Originally Posted by defunct Really got to get my camera back, you're all pointing out the case I already have, pretty much, except for the plastic skin instead of Alum. Mine just has 1inch radius corners which gives it a neater look. Not so industrial. FYI they've got nothing to do with the Samsonite cases I'm on about, go and watch Ronin or a couple of Bond films, one will crop up sooner or later. Samsonite ones are made of single sheets of formed aluminium not fabricated. Sweet smooth lines... Anyhow, if I can pick one of these one up cheap in UK, with right dimensions, I'll do it. If not I'll use HP07s suggestion of countering under the skin, thanks, why me no think o that... I'll be sticking with a quality 15" Iiyama monitor in the case, partly for weight and space, partly for cost/ quality. Probably still cutting holes in the case cos turning up to a corporate conference and fiddling in a box of wires don't look too professional AND still need nuff space for memory sticks to swap files on site. thanks for it all...

If i'm right, hes talking about an attache case. NOT a briefecase. What you're descibing is exactly what came to mind from that one time, single piece for each side and only $45...
This, right?

Unfortunatly, yes, these do start in the $250 range... and Samsonite doesn't even make that style anymore, the new ones are a bit more plain.

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EXACTLY how mine is laid out. I stealthed the drive by removing the front bezel, taking the piece from the tray and glued the aluminum that I cut from the case to it. In the process of relocating the button to open her up. I kinda stopped the project when I decided that cutting the I/O out ruined it. As is the modding way . . . I'll try to get it together again (partly) so I can post a pic if you would like.

Quote: Originally Posted by WrathOfSocrus I kinda stopped the project when I decided that cutting the I/O out ruined it.

Kinda agree, but needs to be done. Especially if I recess it as i've suggested. That would allow for a door of some kind, weatherproof and neat...

How were you fixing things in place?

Just post pics of cutouts and brackets or fixtures if you can be bothered...

Appreciated

Dont even think of bringing that to ANY public place! Man o man, you'd freak everyone out! At airports, they hate metal cases, wires and things that look custom... Freaks the bejesus out of them. But begs the question, why couldnt you bring that?

Quote: Originally Posted by Dreyco Dont even think of bringing that to ANY public place! Man o man, you'd freak everyone out! At airports, they hate metal cases, wires and things that look custom... Freaks the bejesus out of them. But begs the question, why couldnt you bring that?

lol i tihnk ill do it just for the fun of it, ill build one and throw in a ticking clock for good luck and ill see how that goes

Quote: Originally Posted by Dr3w lol i tihnk ill do it just for the fun of it, ill build one and throw in a ticking clock for good luck and ill see how that goes

Make sure to wear a trenchcoat and carry a violin case in the other hand, just for extra good luck.

lol you guys are nutz. I avoid the fuzz like the plague. I have a few pics, but the mobo is in another computer at the moment and the CD-RW is out for further modding. I left all of the foam in for sound deadening. I could thumbscrew a piece of metal or plexi into the mobo that would cover the ports, but I havent decided how soon I'm gonna tackle it. Kinda started a few other projects with way better hardware and left this beast behind. I'll try to get it together this weekend, but no promises.

Quote: Originally Posted by Dr3w lol i tihnk ill do it just for the fun of it, ill build one and throw in a ticking clock for good luck and ill see how that goes

Jack: Was it ticking?
Airport Security Officer: Actually throwers don't worry about ticking 'cause modern bombs don't tick.
Jack: Sorry, throwers?
Airport Security Officer: Baggage handlers. But, when a suitcase vibrates, then the throwers gotta call the police.
Jack: My suitcase was vibrating?
Airport Security Officer: Nine times out of ten it's an electric razor, but every once in a while...
[whispering]
Airport Security Officer: it's a dildo. Of course it's company policy never to, imply ownership in the event of a dildo... always use the indefinite article a dildo, never your dildo.
Jack: I don't own...

Yup guys, the London underground is my main reason for mobility. Gonna have to watch my step for a while...

Anyhow Wrath thanks for pics, I see your problem with the i/o panel. Hope I get a stamped Alum one 'cos that printed one sucks! No offence but I hope to achieve slightly tidier holes than yours but only time will tell.