Project Aim

To design and build a silent multimedia home unit capable of PVR like features

Requirements: Silent, Small Factor, MP3 Server, DVD Playback, TV Playback, PVR Functions (timeshifting etc)

Updated! 6th May 2005

Finally the PVR card I wanted arrived in the UK. I have now fitted the Theater 550 Pro into the case and is all working perfectly! Stage 4 shows the card in place and I have updated the Testing & End Pages too to show it in action.

Looking around at sites in the Mini-ITX community the question "Can I passively cool the M10000" kept coming up. Looking at the board it gave all the functionality/power I need for my project. So there was the challenge. A silent M10000.

First of all I looked at the commercial cases available that peformed such a feet. I wasn't too impressed with some of the designs. The Tranquil got very hot indeed and the Mappit had some nasty design decisions: mounting the hard disk over an area which dissipates lots of heat, not good for reliability! As for the Scythe E-Otonashi don't get me started! The Hush looked the best, but very expensive.


Prototype
For my first prototype I crammed everything into one of Ikea's Karbo cases (as everyone seems to) It all fitted, but it was too small! Too small? Well to cool passively there needs to be room for the air to circulate. As you can tell by the picture there is harly and room left at all! Also the box is a bit naff really; has the key shape in the lid, holes in the back, made of steel, asthetically too, the shape didn't fit with the rest of my gear (hi-fi stuff etc) So I started designing Version 2.
Karbo Box Prototype


Design Process
I started hand drawing lots of technical drawing of the dimensions of the motherboard and placement of chips/sockets etc. Then drew some case layout diagrams. Using the dimensions of the hardware I had I created various layouts until I was happy that their position would use the space available efficiently.

Using the technical data from VIA I enlisted the help of my girlfriend's dad who did lots of complicated maths and worked out what the capabilities of the heat sink solution needed to be. We took as our minimum theta value (ambient air to max junction temperature to 50 - allowing for ambient to 35 degrees) and added a little extra to to be sure. He then cross checked this against some another formula to ensure it fell within the bounds acceptable.
CPU, N/S Bridges Layout

Possible Case Idea		 Now I knew what to build, it was time to get some supplies in! I found a variety of sources for the components used in this project, from the usual electronic component factors, to small familty run businesses located in a barn in the middle of a field! The following stages show how I put it all together...

Next Stage

mr_pdt@yahoo.co.uk © Paul T 2004 : Not to be reproduced without permission.