Hey all. This is a project I've been thinking about for a while. I finally had a stretch of time where I felt i could get it done, and parts had finally become available at a decent price. I had been putting it off for a few years but the past couple weeks i decided to take the plunge.
Most of the hardware was ordered from either mp3car.com or NCIX.com. The front bezel, by far, took the most time. I used completed projects posted on this forum as guidance.
Like many others, I was limited in the type of body filler available. Bondo was the only choice. I sucked it up and went with Bondo Gold. As others had experienced, I was constantly battling with pinholes and little cracks. After many hours of sanding and reapplying, I was able to get it into acceptable condition. It still looked like crap, but at least it was taking shape. After a few more touch-ups it came to the point where it was time to paint.
Someone in another thread mentioned they used truck bed liner. I thought this was a great idea, as it's not only tough but creates a nice texture. After many coats, it not only looked 500 times better, but many of the little pinholes and cracks were now covered up by the thickness and texture of the liner spray. After all was said and done, the front bezel took approximately 20 hours.
The only difficulty with the actual computer components, was situating them properly in my glove box without ripping it apart. With the space being so limited, it was tough to get everything in there and secured, while having all the cables connected.
The standoffs for the motherboard were hotglued into thin plywood that I measured and cut to size. Under that, I cut and glued rubber for basic shock protection. For the HDD, i cut metal mounts that also are situated on the same rubber. The PSU was mounted upside down on thin plywood.
Below are some basic specs for what I installed.
8" Lilliput 809GL-80NP/C/T
Lacie slim DVD writer
4-port USB hub
BU 353 GPS receiver
In the glove box:
Intel board and Atom 1.6 ghz processor
2 GB ram
500 GB HDD (2nd one on it's way )
M2-ATX 160 watt PSU
D-link 802.11 A/B/G wifi PCI card
Factory Monsoon system, with Peripheral AUX-IN kit.
Seems I need to clean up some wires still, and the carpet!