Book Server Project

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Purpose:

The goal of this project is to create a non-obtrusive computer that can be at home in the living room as well as in the office. The computer will ultimately be running Windows Home Server which will allow DNLA support for a PS3 (or XBox360 and Wii). Windows Home Server would be running scheduled backups and the Book Server (as I like to call it) will also be servering video and audio files to the PS3.

The computer had to be low power hardware since it will always be on. It also had to be very quiet to not bring attention it itself. I picked the Jetway motherboard with Via C7 processor which has a VIA CN700Chipset with integrated VIA Unichrome Pro AGP Graphics. The Via based board claims to have MPEG-2, MPEG-4 and WMV-9 acceleration which makes it suitable for this use. The motherboard consumes less than 20 watts at full load and with the laptop hard-drive, it makes for a very energy efficient little 'server'.

Parts:

• Jetway Hybrid J7F2WE2G Mini-ITX motherboard with 2 GHz Via C7 processor
• 1 gig PC-5300 DDR2 RAM
• Gigabit LAN daughterboard adapter
• picoPSU-120C-DC ATX PSU
• Power adapter: AC-DC 12V, 5A Switching Power Adapter (110/220V)
• Seagate Momentus 5400.3, 100 gig 2.5" PATA laptop hard-drive
• Adapter for SATA to eSATA (for future addition of fast external storage)
• PCI Power bracket for securing the plug-in for the power brick to the picoPSU
• Donor Case: Enlight low profile Mini-ATX/Mini-ITXcase (7396AM1)
• Book Server case: Bombay Company Memory Box Part# 1834589
• Lexan for a window into the Book Server.

Procedure:

1. The donor case was disassembled down to the metal frame. The circuit board containing the power switch and LEDs were saved. A section of the motherboard tray that will ultimately house the Mini-ITX motherboard was cut out.

2. The motherboard tray was prepped and painted to remove all the blemishes caused by cutting the tray out of the case.

3. Below is the wooden case before it will be modified to accept the motherboard tray.

4. The motherboard is test fitted after it is painted with silver enamel and laquer applied to give it a sheen.

5. The bottom of the case is painted to match the MB tray. The edges of the port opening and the backplane are painted gold.

6. A hole was cut for the fan, but unfortuantely due to a inadverent distraction, I cut the hole into the front of the case rather than the right side near the back. The Lexan sheet was cut to size to cover the opening so people can see, but not touch the innards when the 'book' is opened. The fan hole edges will be covered with a plastic cap in the future to make it stand out less.

7. The case is ready to accept the motherboard and hard-drive. Still have to do some minor cleanup on the port opening and hole for the fan. The power switch and LEDs will be mounted to the lexan sheet.

8. Below is the Jetway Mini-ITX motherboard. It is around 6" square and around 1.5" high. You can see the picoPSU 12v power supply behind the PS2 connectors. It has 2 std molex and 1 mini molex. There is a power connector that the AC-DC power adapter connects to.

9. The hard-drive and motherboard are now installed. I should have gone with an SATA 2.5 hard-drive because the PATA 2.5 cable blocks the fan too much. I went with the PATA 2.5: drive because I got it for a good price. In the future I may swap it for a 2.5" SATA or create a new mounting plate for a 3.5" drive.

The hard-drive plate and motherboard tray are connected together with a grounding wire for earth ground to reduce static from the case and also to protect in case of electrical ground fault.

I decided to mount the power switch, power connection and power-on LED to the backplane.

Chapter 2 - Final Assembly and Testing (click here)

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