Having a 1U empty metal box laying around, I decided to build a new case for my HTPC
System config is the same as my previous ML03:
i3-2100 (soon to be i3-2120T)
2x2048 MB (Kingston VLP low profile)
Terratec Cinergy S2
2x Hitachi 5K750-640
(sorry... the WD10EARS didn't fit
The empty box I used is one of those "slim-line" boxes made by Hifi2000 in Italy, they're available in various sizes, 1U or 2U, aluminium front (silver or black) and back, extruded sides and steel covers (alu covers available as option), they are bare so to fit a complete PC system there's some DIY to do
The system I'm building can house two half-height, half-length cards side by side with a modified bracket (DVB-T and DVB-S2 cards), a full-height, 1/3-length (i.e. length of the PCI contacts) card over them (audio card), and a fourth half-height, half-length card over the standard mATX slots, using the first one with a 1U riser card, standard HH bracket. For the cooling system, I have some LGA1155 HSFs on the way, an active one with a 75x75 blower and a passive one, will experiment once they arrive with my i3-2100 and soon i3-2120T.
Box measures 415x40x280 mm inside (16 1/3" x 1 1/2" x 11"), standard 1U rackmount on the outside (will cut out the ears to fit in my Hi-fi system).
Testing position with an old P4 mobo.
Drilling fixing holes and checking mobo height, in the end I used two M4x12 steel washers and one M5x15 nylon one. I had to carefully cut all the protruding pins on the underside of the board...
Drilling more holes to fit the backplate (center 3 ones) and to ease work when mounting the heatsink (the 4 squared ones)
First test with the Sandy board
Placing a piece of insulating plastic.
And now the first heavy DIYing: making the back plate ATX ports
First riser card tests
Opening the expansion slots.
DVB-T card fixing on the underside, no need for L-shaped brackets
PLacing some Lian-Li HTPC feet
Testing 3.5" drive clearance with DVB-S2 card and its aux power jack.
Testing cards clearande and placement.
Testing HH slot with standard bracket, no plan to use it ATM.
Placing mobo to check proper mounting of everything.
More to follow, I'm still building it