I did all the same things to my case -- using my dremel tool.
My case started out as a metal key box from Ikea (based on a suggestion/thread I read in this forum last year ). That box works great for mini-itx, but any metal key box or security box matching your measurement needs should work. The box I selected, approx: 7"L x 10¼"W x 2¼"D.Originally Posted by Arathranar
For my application, I decided the following:
top=side of box with lid;
bottom=side of box opposite of lid; I mounted my mini-itx mobo to the bottom inside the case
end=side of box measuring 7";
side=side of box measuring 10¼";
I cut one end (a 7-inch side) out of the box to allow accessibility to the motherboard connections (for my video, usb, power cables, etc...). I also run my power cable from the opus through this open-ended gap. This open-end gap can be filled by the mobo cover-plate provided with mini-itx board, but I just left it open for now.
Next I drilled holes along the side opposite of the top lid/hinge (along the 10¼-inch side to allow air flow for fan). This may or may not be necessary, but what the hell… I did it with good intensions
Next, I performed a “fit-test” of my intended fan/fan grill locations by duck-taping both the fan and fan-grill to the box in the intended location. Next I closed the lid with fan and fan-grill attached and verified the fan did not interfere/touch the motherboard. I also verfied the lid would close with the fan/fan-grill attached. After the fit-test checked-out OK, I cut a circular hole on the top/lid of the metal box measuring approx. 3" in diameter. Once cut, I fine-tuned the cut to fit the fan and fan grill I selected. After shaping the cut-out, I mounted the fan and fan grill to the inside of the lid. Even though I mounted to the inside of the case I still have complete access to the motherboard. For those still reading and keeping score… I mounted my laptop hard drive to the lid also.
Finally, I drilled four holes to the inside bottom of the case matching the locations on my motherboard.
After drilling, cutting, sanding, I painted the case with a flat black paint, and mounted mobo mouting screws, and mounted the mini-itx motherboard, with the connection side facing the opening cut from the one of the ends of this box. This case is stored under the rear seat and houses a Via M10K Mini-ITX.
A final note regarding my experience mounting a M10K mini-itx into an Ikea-Karbo box -- It is a tight-fit.
I had to remove all my components/connections, etc... and mount the board first, to clear the lid/etc. I also cutout a small portion of the back of the lid/hinge to ease installation for my mounting process. I reattached all my components (memory, ide cables, power cables, etc…) after the board was mounted.
Let me know if you’re interested and I will take / post some pictures.