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Thread: Designing a double-din case for 2003 WRX

  1. #31
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    Mounting the LCD...

    I've decided I'm going to go with an 8.4" 800x600 LCD, from eVision Displays.

    I got a quote for the LCD panel, at $428, detailed in this thread:
    Possible 8.4" LVDS 1024x768 LCD?

    The panel mentioned in the other thread is the replacement model of the LCD I mentioned earlier in this thread - the new one is brighter, I believe.

    Total cost for 1 LCD + all the parts was about $511.


    In any case, now that I've settled on an LCD, I started figuring out how to mount the LCD to the front of the case - with brackets.

    The brackets mount to the front of the case, at the edges, and flare out to match the width of the LCD panel frame.

    The brackets, when bent, extend out about 20mm.

    The bracket for the right side of the LCD is bent at 90 degrees, and the bracket for the left side is angled out at about 15 degrees.

    The left side border of the LCD panel is wider than the right side, so the bracket needs to bend out farther to reach the edge.

    About the pics:

    In pic 1, flip the outer edges of the brackets up, and then rotate down to get some idea on how they mount.

    In pic 2, flip the outer edges up, and then you'll have the front-on view, or what the brackets would look like just behind the LCD panel.


    The brackets will be drilled & tapped for mounting holes - the brackets will screw to the front of the case, and the LCD will get screwed to the brackets, through the mounting holes on the LCD frame itself.

    The actual dimensions of the brackets aren't currently 100% yet, as I have to make them equal height.. in progress.

  2. #32
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    Are you going to mount the LCD to the case or to the bezel? Are you going to stick with the mini-itx board or go for a nano-itx board?

    Keep us posted on the progress of your case design...

  3. #33
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    Quote Originally Posted by jmbickham
    Are you going to mount the LCD to the case or to the bezel? Are you going to stick with the mini-itx board or go for a nano-itx board?

    Keep us posted on the progress of your case design...
    LCD brackets will be mounted to the case, and the LCD will be mounted to the brackets - so the LCD will be mounted to the frame, and not the bezel.


    Since the 8.4" screen is as wide as the double-din, but taller, I'm going to have to take the original bezel, make a duplicate of it, and modify it so that the opening is taller.

    Making a duplicate is easy - I have experience with building rubber molds and resin casting complex items.

    The bezel opening will have to get enlarged by about 3cm vertical, which will force the angle of the LCD mount to change by a few degrees.

    Also, since the LCD panel is much taller, the A/C controls below the radio will have to go - to be replaced by a computer-controlled servo/relay mix - THAT design still has yet to be determined.

    In place of the A/C controls will most likely go some peripherals, like the slim DVD drive, cooling fan inlets, etc.


    Of course, I just realized this means that the LCD brackets will probably have to be re-designed to be adjustable for vertical angle.. bah.


    Anyway, about the Nano-ITX - I haven't really looked at them yet.

    I'd like to use a board that has the Pentium M mobile CPU's, to give it some power and low heat.

    There were also some industrial Single-Board-Computers (SBC) that I was thinking might do the job, and are not limited by the Mini-ITX square layout.

    Such as: http://www.boser.com.tw/products/sbc/hs4705.htm

    I'd like to have a board that has PC Card and Compact Flash on-board, as well as the Mini-PCI, so I'm still kind of thinking of the Commell LV-671.

    However, the availability of this board is limited, and the price has jumped to about $450, not including the CPU..

  4. #34
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    Quote Originally Posted by Giuliano
    The material I picked was Aluminum 6061-T6, 2mm thick,

    Edit: Updated for material thickness (2mm vs 1mm), picture, and cost.
    dunno if you know/have considered this but I would test some T6 for cracking when you bend it as you may need to adjust your bend radii or chose something a bit more ductile. I think the 6061 is an industrial grade alloy (used in bikes etc) and i don't know the exact properties but the T6 process makes the alloy much harder and increases the yield strength which normally makes it more brittle. There are lots of parts made from T6 in this way and its generally a nice material to work as its quite stable but if you are doing the bending by hand it would be worth doing a test just incase as it would be a shame to get it laser cut and then snap it! I think the usual bend radius for T6 is at least 2 to 2.5 times the thickness (O, T3 etc need about 1.5) and believe bending at 90deg to the grain may help (no good for a square box with bends at all sides).

    To be safe i would use at least 4xthickness or you could possibly heat it locally when bending. (an alternaive would be to use a lower grade hardening like T4 but i personally dont like T3 so wouldnt go that far).

    Hope this helps and good look, should be a really nice neat design. Gonna have to make a whole new lower console for my 306 if i want a 7" screen.

  5. #35
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    Just FYI, the Commell LV671 costs a whopping ~400USD, and if you want the top of the line Pentium M 1.7ghz thatll run you anohter $400.
    2003 Subaru Impreza TS
    Staus: Done.. too lazy to make pictures lol.

  6. #36
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    Quote Originally Posted by Maeveth
    Just FYI, the Commell LV671 costs a whopping ~400USD, and if you want the top of the line Pentium M 1.7ghz thatll run you anohter $400.
    Yeah, it's not cheap, I'm aware of the cost.

    Quote Originally Posted by Giuliano
    I'd like to have a board that has PC Card and Compact Flash on-board, as well as the Mini-PCI, so I'm still kind of thinking of the Commell LV-671.
    However, the availability of this board is limited, and the price has jumped to about $450, not including the CPU..
    A higher part cost only means it might take me longer to acquire all the parts.

    The appeal of having CF and PC Card on-board is strong.

  7. #37
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    Quote Originally Posted by Scouse Monkey
    dunno if you know/have considered this but I would test some T6 for cracking when you bend it as you may need to adjust your bend radii or chose something a bit more ductile. I think the 6061 is an industrial grade alloy (used in bikes etc) and i don't know the exact properties but the T6 process makes the alloy much harder and increases the yield strength which normally makes it more brittle. There are lots of parts made from T6 in this way and its generally a nice material to work as its quite stable but if you are doing the bending by hand it would be worth doing a test just incase as it would be a shame to get it laser cut and then snap it! I think the usual bend radius for T6 is at least 2 to 2.5 times the thickness (O, T3 etc need about 1.5) and believe bending at 90deg to the grain may help (no good for a square box with bends at all sides).

    To be safe i would use at least 4xthickness or you could possibly heat it locally when bending. (an alternaive would be to use a lower grade hardening like T4 but i personally dont like T3 so wouldnt go that far).

    Hope this helps and good look, should be a really nice neat design. Gonna have to make a whole new lower console for my 306 if i want a 7" screen.
    Well, I had chosen 2mm thickness as a general good guess, and as far as aluminum goes in that thickness, I have a choice between Aluminum 6061-T6 or 6063-T6.


    However, I do have a choice of several types of steel - really, too many types for me to easily pick one.

    Choices:

    Steel, Carbon Grade C-1018
    Steel, Carbon Type 1010, 1015, 1018, 1020, 1040
    Steel, Case Hardening 8620
    Steel, Constructional 1040, 1055, 3310, 4140, 4340, 52100
    Steel, Mild 1008

    Among others..

    Could anybody with material knowledge suggest a better material?
    Aluminum or steel, either way. Steel's much less expensive.

    It's going to have to be about 2mm thick, be fairly bendable/ductile, yet still suitable for tapping 6-32 or M3 threads.

    Most of the bends will most likely have a 2mm bend radius or thereabouts, and the bends will be done by the machine shop.

  8. #38
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    First off I want to say that this post is in no way shape or form intended to be argumentative. Its only a means to bounce ideas off anohter person and vica versa. No flaming please 8 )

    Quote Originally Posted by Giuliano
    A higher part cost only means it might take me longer to acquire all the parts.

    The appeal of having CF and PC Card on-board is strong.
    One thing you could consider is that Commell is not a large company so if you have problems with the board chances are it will be somewhat difficult if not near impossible to get support of the board and since you just put down ~400 on the board well you get my point. This however is not proven fact yet and they could have GREAT customer service.

    Also the VIA EPIA MII-10000 has optional built on CF and PCMCIA, however neither are bootable but I dont see this as a problem because the only advantage of booting from a CF card is that its solid state but your boot time will be higher, not to mention the cost of getting one large enough to store windows, not to mention media. But if your going to buy a stardard harddrive you may as well just not bother with CF. Carpod(http://carpod.ca) has the MII with the CF/PCMCIA module. The other advantage of this is that your spending ALOT less - ~200USD for Mobo+CPU.

    The problem I see is that the C3 Eden chips dont preform as well as a Pentium M. This should not be a problem because 1, the 1GHz C3 can play back divx movies full screen without skipping from what I've read in benchmarks. ALSO if your worried about DVD decoding the MII-10000 has a built on MPEG2 Decoder chip for doing just that so the CPU will end up mostly idle when playing DVD movies.

    I can see why you want Mini-PCI but I think it is unneccsary since you can put most device on the USB bus. If your worried about a lack of bandwidth on the USB Bus the MII-10000 has 2 USB headers offering a total of 4 USB channels totaling to over 2GBit of bandwidth(theoretical max). Unless you plan on hosting a massive File server in your car I dont aticipate that this will become an issue.

    Again this post was not intended to be argumentative.

    EDIT:
    P.S. Im jealous you have a WRX
    2003 Subaru Impreza TS
    Staus: Done.. too lazy to make pictures lol.

  9. #39
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  10. #40
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    Quote Originally Posted by Maeveth
    First off I want to say that this post is in no way shape or form intended to be argumentative. Its only a means to bounce ideas off anohter person and vica versa. No flaming please 8)
    No need for an asbestos-suit on my part - I rarely flame anybody.

    Quote Originally Posted by Maeveth
    One thing you could consider is that Commell is not a large company so if you have problems with the board chances are it will be somewhat difficult if not near impossible to get support of the board and since you just put down ~400 on the board well you get my point. This however is not proven fact yet and they could have GREAT customer service.
    True, the boards are still fairly new to the market.

    However, Commell also makes industrial backplane-capable Single-Board Computers, so they're not just a PC motherboard manufacturer.

    Quote Originally Posted by Maeveth
    Also the VIA EPIA MII-10000 has optional built on CF and PCMCIA, however neither are bootable but I dont see this as a problem because the only advantage of booting from a CF card is that its solid state but your boot time will be higher, not to mention the cost of getting one large enough to store windows, not to mention media. But if your going to buy a stardard harddrive you may as well just not bother with CF. Carpod(http://carpod.ca) has the MII with the CF/PCMCIA module. The other advantage of this is that your spending ALOT less - ~200USD for Mobo+CPU.

    The problem I see is that the C3 Eden chips dont preform as well as a Pentium M. This should not be a problem because 1, the 1GHz C3 can play back divx movies full screen without skipping from what I've read in benchmarks. ALSO if your worried about DVD decoding the MII-10000 has a built on MPEG2 Decoder chip for doing just that so the CPU will end up mostly idle when playing DVD movies.
    The CF/PC-Card availability is important to me not because of the boot-ability, but for peripherals - a PC-card GPRS wireless modem, for example.
    (not to be confused with 802.11x Wi-Fi)

    I'd prefer the Pentium M over a Via CPU for general-purpose CPU power for multitasking - I'm not really planning to play movies/DVD's, but more for GPS navigation with Microsoft Mappoint, which requires some CPU to work well.

    Quote Originally Posted by Maeveth
    I can see why you want Mini-PCI but I think it is unneccsary since you can put most device on the USB bus. If your worried about a lack of bandwidth on the USB Bus the MII-10000 has 2 USB headers offering a total of 4 USB channels totaling to over 2GBit of bandwidth(theoretical max). Unless you plan on hosting a massive File server in your car I dont aticipate that this will become an issue.
    It's more of a "keeping my options open" decision - Mini-PCI is a standard, and there are lots of options available in Mini-PCI.. anything available in Mini-PCI would work. A video-capture board, for example.. rear-view camera?

    Quote Originally Posted by Maeveth
    Again this post was not intended to be argumentative.

    EDIT:
    P.S. Im jealous you have a WRX
    Not a problem.

    And my WRX isn't much to be jealous over - it's only a wagon, and only a 2003, not a 2004 or STi.

    And it's still completely stock!

    But it still is rather fun to drive..

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