HTPC Case Mod - Part 2

January 6th, 2008 by erb

(Part of a porting project from static web pages to blog… Original air date: 27aug2007)

This blog entry is for my original HTPC plan, using a VIA EPIA M10000 motherboard. Initial evaluation of that choice proved unsatisfactory for decent video playback performance. I looked into non-VIA options, including AMD and Intel solutions — with the caveat that whatever I chose, it must fit within the restrictions of the SCSI enclosure mods to date. Power requirements were also a major consideration.

Ultimately, after much evaluation, I went with the Jetway J9F2-KHDE, a Socket 479 motherboard with dual DIMM, rear CPU, Gig-E, DVI, VGA, HDMI, 2xSATA, PCI32, and multiple CPU support. I used a Core 2 Duo Mobile T5500 FSB667 1.66GHz, and 2x DDR2 667 1GB (2GB). I dropped the original Dual-PCI Riser option described below, which was used for RAID and Wireless-G PCI cards. Instead, the PCI32 slot is used for the RAID adapter, and I bought a Wireless-G Mini PCI card – an option unavailable on the M10000. This setup has exceeded my expectations!

I’ll describe the mods and setup required for this “HTPCv2″ in more detail in a subsequent post — as well as details for the Quiet Fanless Linux (Debian?) Dev Box, using a Serener GS-L05, that I will put the M10000 into. Without further ado…

Original SCSI Enclosure Mod Details, w/EPIA M10000

Ever since getting a Series 2 TiVo to replace our aging Series 1, I’ve wanted to finish making an HTPC computer for the living room. I was planning to use an old Sony AV enclosure, mod’ed to hold a VIA EPIA M10000 motherboard, an old PATA drive, and a VFD display (with IR remote). But… I was never too keen on how that was shaping up. I also wanted to make it nearly silent, and tried using a solid-state 4GB 2.5″ Flash IDE HDD. That work stalled when I had some difficulties getting Windows XP to fit cleanly in 4GB, what with the various system update patches using too much disk space. Clearly a drive re-partition, post-install/update, was in order, and I never found time to dedicate to finishing this.

SCSI EnclosureRecently, I looked at a number of cases for the NEW HTPC, including:

I ended up choosing the SCSI enclosure mod, since it was smallest, free, and most of all — the mod challenge! Full info on each case — dimensions, review links, visual size comparisons — can be seen on my original Mod web site (cases).

Case requirements

  • Need to fit the Mini-ITX mobo, 170 x 170mm; not a problem in general for the cases – but moreso for the SCSI mod
  • Need to fit appropriate HDD enclosure; Either 3-in-2, 4-in-3, or 5-in-3
  • Need to fit appropriate power supply of sufficient wattage

A detailed overview of SCSI enclosure and HTPC component considerations and layout is available at my original Mod web site (measurements). I describe trade-offs required between (a) using a Dual-PCI Riser to support both a RAID controller and a Wireless-G card, versus (b) using a single PCI card, forego the wireless option. The dual option (a) has a drawback: the drive enclosure gets pushed out of the case front slightly (~1 cm), whereas option (b) has no such issue. While I went with option (a) in this original M10000 build, the later Jetway build only uses the single RAID PCI card – and the drives look much better flush! Better overall cable management, as well. Other components include a slimline optical drive, and a VFD display underneath the drive enclosure

Power requirements

For details and a complete estimated power budget calculation, see my original Mod web site (power). I went with external AC/DC power brick adapter, and two picoPSU power supplies, one for the motherboard and a second dedicated for the 3x SATA drive enclosure. Estimated worst-case power requirements were largely based on results from the Epia Center powersim web tool:

  • For the M10000 motherboard, 50-60W can be satisfied using a picoPSU 80W
  • For the drives, I figured 3x 40W = 120W (mostly 12V), using a picoPSU 120W

Other components

For evaluation details, see my original Mod web site (HDD enclosure), as well as (RAID controller), (drives), and (PCI). I went with:

Pictures!

SCSI Full-Height enclosure: Original; with cover removed; with SATA HDD backplane/drive enclosure installed.

Rear view, exploded view, power supply.

SCSI 3.6GB drive.

IcyDock MB453SPF-B 3-in-2 SATA backplane/enclosure. Note the rear placement of the fan, and the Molex/SATA connectors.

Interior views of the SCSI enclosure. Bottom width is not quite wide enough for the 170×170 mm mobo, certainly not when inserting/removing. I’ll have to dremel out a slot on each side. The stock fan will be replaced with a standard 80 mm fan.

The Epia VIA M10000 motherboard, with picoPSU 80W power supply attached. Note I’ve already mod’ed the PSU to attach a wire (+5 VSB) leading to the VFD display, which supplies power on functionality via an IR remote control.
We also have the two PCI cards: Linksys Wireless-G WMP54G, and Promise TX4310 SATA RAID controller. Note both are flush with the PCI slot depth, 120 mm. The RAID controller has ports 3 and 4 on the rear of the card, and I need to use port 3…

Some views of the enclosure with mobo, after dremeling out slots. Note PCI slot positioning — it’s flush with the edge of the enclosure, and I’ll need to dremel out a bit more for proper insertion of the PCI extender ribbon. Adding front panel, optical drive, and IcyDock.

After a bit more modding and dremeling and fitting, taking my first trial run. First and only difficulty so far: The optical drive wasn’t recognized by the BIOS, although it does have power. I’m guessing the round IDE cable is suspect, which is a shame (it is a really nice cable, with flex nylon sheathing, much nicer than the usual rubber cables). Also, assembling/disassembling this case is a real bitch. The primary IDE controller is working just fine — the 4GB flash drive was seen no problem. I ended up “installing” an old 1x CDROM drive in an IDE PATA USB/Firewire enclosure, set the BIOS for Third Boot Device = USB CDROM, and it booted fine! But it was very slow … Took at least half an hour for Windows XP install disk to boot to first prompt.

Note the extended screw slot guide for the enclosure, and the IcyDock enclosure sticking out the front more — it’s not as bad as it looks here, with the front panel on you only see black.

The two connectors in the rear are for a power button, routed to the VFD display (which drives the actual PSU power on, integrated with IR remote control). I’ll probably just use the original power switch.

You can see the secondary picoPSU mounted to the IcyDock 80 mm fan, using cable ties. I only did this as a temporary measure, but I’m seriously thinking of using it as my permanent solution: it holds tight, and yet when assembling/ disassembling, it is quite easy to slip off.

Murphy’s Law strikes — I didn’t test the blue LED fan until assembling everything, and I installed it backwards (pulling air into case). There weren’t any arrows indicating direction either. Both fans are surprisingly quiet, so I don’t see any need to buy an expensive case fan. The blue LED fan does have a nice soft glow, and hooked up to mobo SYSFAN, the BIOS reported speed correctly (about 3000rpm).

Nice cabling job, huh? A number of 90° bends, one near-180° bend (port 3, from rear of controller, butting up near the IcyDock, routed along back of controller to rear of card); a number of cable ties holding things tight and immobile. Shorter cables would help, but these are free (they came with the TX4310 controller).

(Ed. Note: In the HTPCv2 J9F2-KHDE build, with the previously mentioned single-PCI slot option, several factors improved this mess significantly: (1) Without the PCI riser / dual slots, there are no longer any cards extending all the way against the IcyDock; (2) The PCI RAID controller fits flush next to the IcyDock, so the rear port 3 cable can connect freely and directly, without any bends; (3) I bought some short 90° angled SATA cables, improving cable flow.)

Posted in HTPC

One Response to “HTPC Case Mod - Part 2”

  1. Thanos Ubuntu Linux Mozilla Firefox 2.0.0.13 wrote on 04/11/08 at 12:01 am :

    Hi
    please elaborate on “unsatisfactory for decent video playback performance” - I’ve been using M10000 (1GHz) for more than 2 years now - currently Ubuntu,MythTV 0.20, Hauppauge PVR-150 - and I get decent DVD playback (~85% cpu), liveTV at about 45%, record + playback of other stream at about 55-70%.
    I’ve considered many times to upgrade the H/W but always at the end I found no real reason…

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