Log Project *Pac-Man*. Slim wall-mount 12.5L case

[samsonbl4]

Hi!

While I finish up my second wall-mounted SFF build, I can start preparing for the third one. This time, I won't be building a case for actual use, but rather to test out technical and manufacturing solutions. I’ll be using my first case project as a starting point. The chassis will have the shape of a "pizza box" console and will be constructed from 1 mm sheet steel.



The goals of this project are:

- To replace corner welding with a riveted joint and evaluate the assembly precision and rigidity of the actual product. I like welding because it gives the enclosure a solid, monolithic look and high rigidity, but it is not an optimal manufacturing solution, and the quality depends heavily on the person performing the work.

- To design a wall-mounted bracket and use a furniture suspension rail on the wall for it. This solution ensures a flush fit against the wall but—unlike using slots cut directly into the unit's body—simplifies installation and allows for minor adjustments. It also improves weight distribution.

- To design the power supply bracket so that it takes up minimal space and provides convenient access to the IEC C14 connector.

- To create a perforated top panel featuring a *Pac-Man* level design; I believe this is a nice concept for decorative perforation that also ensures good airflow.

- To create an attractive design for the detachable legs

- To support two types of risers in the chassis: 90-degree and dual-reverse. A dual-reverse riser is better suited for this layout and allows for the installation of thicker cards, whereas a 90-degree riser is easier to find on the market.

- perhaps something else...

- to spend free time in an entertaining way





Specifications and compatibility targets:

Thickness - 85mm;

Volume - ~12L;

Motherboards - mini-ITX, mATX (up to 225×243 mm);

CPU cooler height - up to ~60 mm;

Graphics cards: length up to ~320 mm, thickness up to ~60 mm (3-slot);

PSU: SFX, SFX-L;

Drive bays: wherever there's a free spot left



UX-solutions:

- flush-to-wall mounting;

- downward-facing ports;

- easily removable feet for surface placement;

- side-mounted USB-C port.



At the pre-CAD stage, I would like to get your ideas regarding UX-solutions suitable for a wall-mounted SFF format.

 

[samsonbl4]

So, I’m gradually working on the design. At this stage, I have settled on the layout and the main structural elements of the chassis..

Here are the resulting specifications:

• Case dimensions: 367x377x90,8 mm
• Volume: 12.5 L
• Material: 1 mm steel
• Mount to the wall with a ~5 mm gap
• PSU Support: SFX, SFX-L
• Cooling: Up to 67 mm CPU cooler height, 4 x 80x15 mm case fans

Compatible components if installed 3,5-slot GPU:

• Mobo: Mini-ITX
• GPU: length up to ~340 mm, width up to ~150 mm, thickness up to ~70 mm (3.5-slot)
• Drive bays: 2×2.5’’
• Double reverse PCIe riser cable

Compatible components if installed 2,5-slot GPU:

• Mobo: Mini-ITX, mATX (up to 225×244 mm)
• GPU: length up to ~340 mm, thickness up to ~50 mm (2.5-slot)
• Drive bays: 1×3.5’’ + 1×2.5’’ or 2×2.5’’ (if installed Mini-ITX + 1×2.5’)
• Double reverse PCIe riser cable or 90-degree PCIe riser cable

In my opinion, the riveted angle brackets look pretty good. I had expected them to look worse.
At first, I wanted to make the case thinner, but there are many good coolers on the market with a height of 67mm, so I decided to increase the case height. However, the clearance between the cooler and the top panel will be very tight, so I’ll need to include plenty of ventilation perforations in that area.
Now, all that’s left is to design the top panel in the style of a *Pac-Man* level and design the legs where they attach to the rivets at the bottom.