This Old Server, Part 4: Finished!

Dell Server Case 2013-10-05 022

Following up from last time.  Here’s the new front panel mounted in the Dell case.  The ugly patched-up component on the right is a old USB front panel that has been much abused.  Part of it is taped off because it is an audio panel I don’t use and don’t have connections for in the server.  The other part is taped off because I snagged a thumbdrive in the port one day and the port broke off to save the drive!  The hard disks are already mounted in their cage.  On top is a Blu-Ray drive from my old server.  You may have seen a DLT drive in the old machine earlier in the series, I didn’t install it because it is SCSI and I have no card for it.  I also wish I could have saved the original PERC RAID card, but it does not fit.  Maybe eBay, someday.

Here’s another shot of the inside:

Dell Server Case 2013-10-05 015

At this point, the system is just about complete.  There are two USB connectors on the original Dell.  I’ve wired extensions to these with an old USB cable that I cut up for the purpose, so I have 4 USB ports up front.  The small card in the foreground is an external SATA controller that I use with my backup drives.

There are just a few loose ends.  I mentioned before that I used my old Tyan board to mark out holes to drill for standoffs.  The Supermicro is a mini-ATX board and some of the mounting holes did not line up.  The board is secure for now but I want to fix this by marking new holes and removing the board to drill new ones, so that all seven screws will secure the board.

I also have to work on the fans.  The Dell 1800 used two large (120mm) fans.  One was a case fan—it’s the black plastic casing on the bottom right;  the other fan mount can be seen on the top left.  This was originally part of a air shroud that cooled the CPU.  (Again, I forgot to take pictures, but most of Dell’s servers have elaborate shrouding and air flow management.)  I haven’t mounted that fan.  I’m wondering if a thin-profile 120mm fan would fit in the drive cage;  it does get hot in that area.

The Dell 4-pin fan wiring will work on a modern white-box server board, but the connectors aren’t compatible.  Also, these are big fans that draw 2.5A, much more than the 0.5-1A fans that most white-box boards have, so I don’t dare try running them directly from the motherboard.  I did get one fan working on plain 12V without tachometer control but it is loud so I disconnected it.  The Supermicro already ran much cooler than the Tyan, and even more so in the new, roomier case, so I’m not worried for the moment.

(Fun fact:  When I took the old Tyan board out of my old server case, it was still hot in my hands!)

My server, complete!  Notice the white LED for power:

White box in old Dell case

There used to be Intel Inside, but not anymore!

Inside my Dell PE 1800.  Now with a Supermicro H8SCM-F.

A case like this would have cost me well north of $200;  when I originally spec’d out my machine earlier this year, I was really worried that I’d have to house it in a cardboard box because suitable tower enclosures were either unobtainum or expensivum.

I may not be cut out for casemodding, but the results seem to be good enough.   Happy casemodding!

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One Comment on “This Old Server, Part 4: Finished!”

  1. […] This Old Server, Part 4: Finished! This Old Server, Part 2: Drilling, Grinding and Wiring […]


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