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g5 mod modding powermac apple

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#61
Ira Aduro

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I make these in illustrator so I can save as that, EPS, SVG or even as a JPG or TIFF file.

Talking to a friend and he had the great suggestion that I take the plans down to a local tech college as they often have a shop and will cut stuff out. The company I called about get this cut out with a water jet also have a CNC router but they flat out refused to cut it with that since they said all the up and down of the holes would destroy their motor.

EDIT:
I updated that post with a .zip file that contains EPS, SVG, AI, DXF.

#62
Baudouin

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Funny excuse, destroy their motor !! I could open the three other files. Thanks, but there are too big except the ai file I could reduce it to the real size .

#63
Ira Aduro

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When you open the files you may have to tell it what the scale is. In this case, 1 unit = 1 mm

#64
Ira Aduro

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So I tweaked the back cover to have less holes and cover less area.

I need some advice from those that have cut backplates. The expansion slot area - it seems the facade is glued or welded to the back of the case? If that is so, my current plan is to cut right below where the expansion slot begins and remove the perforated aluminum there. How well do you think that would work?

In case that is not clear I've attached the template with red areas showing where the expansion slot and latch would go, you can see how close it runs to it. Oh and the three larger holes in the area above the rear IO area is a place where I'm thinking about attaching two wifi and one bluetooth antenna.

Company move is on final week. I promise this mod is going somewhere! Just very slowly and very cautiously. There probably will never be another G5 mod by me so I want to get this one perfect so I can use the case for many years to come.

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#65
Baudouin

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So I tweaked the back cover to have less holes and cover less area.

I need some advice from those that have cut backplates. The expansion slot area - it seems the facade is glued or welded to the back of the case? If that is so, my current plan is to cut right below where the expansion slot begins and remove the perforated aluminum there. How well do you think that would work?

In case that is not clear I've attached the template with red areas showing where the expansion slot and latch would go, you can see how close it runs to it. Oh and the three larger holes in the area above the rear IO area is a place where I'm thinking about attaching two wifi and one bluetooth antenna.

Company move is on final week. I promise this mod is going somewhere! Just very slowly and very cautiously. There probably will never be another G5 mod by me so I want to get this one perfect so I can use the case for many years to come.


Not exactly, from the outside, the plastique with numbers is glue to the alu plate and from the inside the "divider" connectors piece is soldered onto the case. It easy to take it out with a flat screwdriver by gently lifting the piece alongside . I will make an How-to with pix because I have dismantled several cases and kept the different parts. :)

#66
Ira Aduro

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!!! awesome !!! thanks in advance.

#67
Baudouin

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In the meantime, the pics :
You can see the glue on the plastique parts and the shadows on the mesh part is the track of the solder .

Posted Image Posted Image

#68
Ira Aduro

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So, another dead end but I am learning. According to the local tech college - cnc cutting the backplate would not be a good idea because the thin metal would vibrate too much and programming time would be too long for a one-off piece. They did recommend me to a laser cutting place as that is supposedly the best way to cut a piece like this. Also, holes smaller than 1/8" are not really round with a laser cutter and you have flash burrs when cutting aluminum since it is so reflective.

#69
nickjf20

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Minihack would be the man to ask -- (thelaserhive)

He's got a laser cutter himself (although I think he uses it mainly for perspex and out sources the aluminium cutting)

#70
WhatTheTech

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We seriously all just need to put our money together and buy a workshop with a laser cutter, plasma cutter, mill, and all those other awesome machines. We could automate everything with arduino so that you could upload your design, it would cut it, inspect it and mail it right back :D

#71
Ira Aduro

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Don't get my hopes up. I thought the hard part would be making a template for the backplate that matches up perfectly. I didn't think the hard part would be finding a way to cut said template out. :(

I've been talking to David from the LaserHive and laser cutting the aluminum would cause warping due to heat build up from cutting so many holes so close together. I've started looking into drill presses so I can do this by hand but that is not ideal. There's got to be something I'm missing. I'm going to contact more CNC places, maybe someone around my town can stably cut thin aluminum. I've also contact a guy from the Hard Forums who has a plasma cutter and offered to cut stuff for me.

The really frustrating aspect is my goal of a backpanel that anyone can download the template for and then have it cut out is looking less likely to happen simply because the cutting out would be $$ or hard to find someone who could do it.

#72
WhatTheTech

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The really frustrating aspect is my goal of a backpanel that anyone can download the template for and then have it cut out is looking less likely to happen simply because the cutting out would be $$ or hard to find someone who could do it.


Well keep up the hard work - all it takes is for one person like yourself to make contact with someone who has the capacity, and it opens the door for everyone else! Looking forward to see if Plasma is the answer!

#73
Ira Aduro

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Good thing I'm too stubborn for my own good. :D I emailed around ten CNC / Laser cutting local places last night with the template, asking for quotes and if they couldn't do it who would they recommend. Sheriff, who originally made the template, cut his out on a CNC machine so I'm not totally buying the "CNC would be too much vibration" line. The first shop I talked to just didn't want to drill that many holes with their CNC machine. Vibrations weren't the issue.

Another option, I think instead of recreating the backplate it might be possible to cut out bits of the back and graft them into place, then graft in a few custom made pieces. So for instance instead of making the fan section, cut it out and move it left. Take the part you cut out to make room for the fans moving left and graft that in to the right of the fans, filling in the gap between the fans and where the rear IO port section would go. You could cut out a custom piece for the rear IO port section. You might need a small 3"x3" section of perforated aluminum made. I'll play around with it more over the week. Here's a rough idea of what it would look like (attached).

Also, been thinking about taking the front CPU fans, cutting out the fan part, leaving just the facade, and turning it into a cover to mask a HD bay. That mean the HDs would have cool air pulling by them thanks to the two 92mms in the back, and I don't think they would make enough heat to negatively effect the CPU if they sat somewhere in front of it.

btw - if you want a dirt cheap but nice camera kit - get a Lumix G3 and a Hexanon 50mm 1.4 lens. All in all should cost you around $380 if you buy the camera without the stock lens and with the Hexanon and needed adapter or $480 with the kit lens, Hexanon and Hexanon adapter.

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#74
Ira Aduro

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Got my first quote back! $115 for backplate_rev2.

Got my second quote back! $215!

:wallbash:

Well I am waiting to hear back from a few others including the guy over at [H]ardforums. We'll see.

#75
MiniHack

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Got my first quote back! $115 for backplate_rev2.

Got my second quote back! $215!

:wallbash:

Well I am waiting to hear back from a few others including the guy over at [H]ardforums. We'll see.

Ira Aduro.
I know we talked about this and the practicalities of all the holes, but the major question in my head is why you would place the board IO so far away from the PCI slot area? Did I miss something or is the back you want to cut NOT meant to conform to the PC (ATX/mATX) standard? Naturally to meet the PC standard the rectangular IO area must be immediately next to the PCI slot area. So if the backplate you want doesn't fit with ATX or mATX motherboards why do you want it?
Anyway, that question to one side and assuming I have misread something in that. There is another option open to you that you could follow - which is to cut from perforated aluminium with a pattern "close" to the original pattern. That is one option my aluminium cutting guy gave me when I started down this route myself a year or more ago. I rejected that one at the time as it would need too much finishing by hand around the cut out areas to make a smooth look and so is not a saleable "off the shelf" kit, BUT it occurs to me that a custom design could be made that'd look quite good and would be a heck of a lot cheaper to produce and an enthusiastic modder might enjoy the extra hours smoothing out areas around the latch/ fan cut outs etc.
Just a thought and feel free to email too - but an open discussion here is also fine for me.

#76
Baudouin

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Posted ImageMiniHack, on 14 March 2013 - 10:00 PM, said:


Ira Aduro.
There is another option open to you that you could follow - which is to cut from perforated aluminium with a pattern "close" to the original pattern. That is one option my aluminium cutting guy gave me when I started down this route myself a year or more ago. I rejected that one at the time as it would need too much finishing by hand around the cut out areas to make a smooth look and so is not a saleable "off the shelf" kit, BUT it occurs to me that a custom design could be made that'd look quite good and would be a heck of a lot cheaper to produce and an enthusiastic modder might enjoy the extra hours smoothing out areas around the latch/ fan cut outs etc.


I tought about that too, found the right pattern but the alu plate is shining.

#77
Ira Aduro

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I rejected that one at the time as it would need too much finishing by hand around the cut out areas to make a smooth look


If the pattern is close but not an exact fit how would you go about making it blend with the original parts of the back?

I'm attaching an image to this post which shows why I'm designing the backplate how I am. I have a UD5h motherboard and my power supply is mounted where the HDDs were. Because of this the motherboard sits lower than mods that place the PSU in the original PSU enclosure. I've marked the two areas where the IO ports would be and the three PCI slots that match up with the bottom three expansion slots of the G5.

In the end I plan on making a few variants of this and one would conform to ATX standards for those that want to place the PSU on the bottom.

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#78
shiftysamurai

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What about water jet and/or laser cutting? Either way should give you fairly good definition/precision.

#79
Ira Aduro

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sadly no, water jet is to $$ due to all the starting and stopping. Laser cutting would cause warping due to all the 3mm holes cut in close proximity.

I'm contacting a second water jet company in town to get another quote.

Talking this over with the guy on [H]ardForums, most likely when apple made the G5 they used punches for the holes. Punches are cheap for large production but setup cost would be at least $200.

#80
MiniHack

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If the pattern is close but not an exact fit how would you go about making it blend with the original parts of the back?

I'm attaching an image to this post which shows why I'm designing the backplate how I am. I have a UD5h motherboard and my power supply is mounted where the HDDs were. Because of this the motherboard sits lower than mods that place the PSU in the original PSU enclosure. I've marked the two areas where the IO ports would be and the three PCI slots that match up with the bottom three expansion slots of the G5.

In the end I plan on making a few variants of this and one would conform to ATX standards for those that want to place the PSU on the bottom.


Okay, that sort of explains it. Sorry if you said that somewhere else but I didn't see it. I get it now, you want the top 4 of the seven PCI slots to be used and are happy to keep the bottom 3 not externally accessible.

I have my first production batch of low sitting aluminium ATX backplates arriving at The Laser Hive next week for the full ATX low solution. Still though obviously avoiding too many small holes cose together because of the 'warp' factor (nowt to do with Star Trek :worried_anim: ). These though will only be available in the 120 style as bringing the lower three slots down the case means not enough room for the dual 92s to sit on the flat area of the panel.

And yes for new backplate made from a 'close' but not identical hole pattern you need either to make the panel full height/width or have a replacement patch that has a nice horizontal crisp dividing line at the point where the original G5 holes and the new ones meet - make a small styling feature of it.





Also tagged with one or more of these keywords: g5, mod, modding, powermac, apple

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