Installing the PSU
Now we were ready to prove the project by putting some working components into the case. Due to structural rigidity concerns, we did not allow for a removable side panel on the case. Therefore we left the top off of the case and loaded all of the components through the top.
Because our case was laid out similarly to a BTX form factor, the first item we installed was the power supply. We chose an Antec Earthwatts 500 due in part to its >80% efficiency rating, which helped to keep the level of heat down inside the case. We placed the PSU on the bottom rails of the case and aligned it with the cutout in the case’s rear panel.
This is a non-working power supply we used to test the form factor
Installing the motherboard
Since we had built the case to micro-ATX specifications, we needed to locate a suitable motherboard. The motherboard we chose utilized an nVidia nForce 430 chipset, which featured onboard sound, networking, and GeForce 6150 graphics. To round out the basic PC components, we installed an AMD Athlon 64 X2 5000+ with stock heatsink and 2GB of OCZ DDR2 on the motherboard.
In order to attach the motherboard in the case, we mounted it to the horizontal poles of the internal case frame. We briefly considered simply taping the motherboard in place, but this would have been contrary to the goals of the project, so we devised a mounting system using common hardware store parts. We placed a 4-40 threaded 3/4” bolt through each of the motherboard’s mounting holes. Each of these bolts was affixed snugly with a nut. Then, we attached a second nut to the end of each bolt, leaving enough room between the nuts for the width of the poles. The bolts then could rest directly on the horizontal poles, without slipping off. Distributing the weight this way, we were able to easily ‘hang’ the motherboard in the case without causing any noticeable stress to the structure or balance of the box.
Installing the hard drive
Next we placed the SATA hard drive in the bottom of the case in front of the PSU, and ran its cables up to the Motherboard.
Finally, the optical drive was placed on its side on the shelf, in such a way that it could be accessed through the door.
All that was left was to plug it in, and turn it on.
The moment of Truth
It worked. The pieces held up securely, and even after being on for some time, the heat did not seem to weaken the tape. Rob even managed a short, choppy session of Me Fortress 2. And of course, we have video.
Conclusion
After working sporadically on the project for nearly a year, we feel that we met all of the goals we set at the outset of this project. We’re happy with the quality of our work, but we learned several lessons during this project that will come in handy during future duct tape endeavors. That’s the great part about working a creative process using a single medium: every time you pick up the tape, you learn something new that will serve you in the future.
To see the rest of the photos taken during the process, visit this Picasa album. If you have a suggestion for a future Duct Tape project, PM CB or Rob here at Icrontic.
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