Bugbyte's 2001 New Beetle -Mac Mini Install - Page 3

Bugbyte · 06-12-2005, 01:18 AM

CRAP. I knew this would happen.

Today, as I was building according to the plan I described in the previous post, I realized that I had forgotten one very small detail. The auto power on cable.

This is a cable that the P1900 power supply uses to signal the Mini to turn on. I bought the "Y" cable splitter that keeps you from having to hack your power switch apart and still be able to hook it up to the P1900.

Trouble is, I haven't accounted for that cable in the docking mechanism.

It's just a little bitty thing, so one solution is to do it like they do those little charging connectors on your cordless phone. When you put it in the cradle, it connects automatically. I could do the same, but have to come up with some way to make that happen. Right now I don't know how to do it.

bellerophon · 06-12-2005, 03:24 AM

Try a Mini-Fit BMI from molex.com I've used em for self docking quite a bit in other projects and you can even get a few for free as samples.

Here's a test pic of my HTPC with one installed.

Bugbyte · 06-12-2005, 12:03 PM

Those are cool! However, I don't think I have the room to add them. Space inside the Mini is extremely limited, so I've only got a very small amount of space.

There are only 2 connections to make. I think I need to pull a McGyver on this one. Something like using the pocket clips from two ball point pens and having them touch two metal contacts or something like that.

Bugbyte · 06-12-2005, 06:16 PM

Although it doesn't look like it from the "finished product" output, I made good progress this weekend. Here's a photo of the project right now.

I completed the shielding for the cables to protect them from the heat in the heat/Air cond. duct. It's the stuff in red in the picture above, while the dock itself is in yellow.

I went out to the car and tried to take as accurate a measurement as I could of where the ductwork begins and it's location so I could attach the dock to the center console. I drilled two holes in either side of the dock and put screws into it, fixing its position in the center console.

Then, the moment of truth -test fit number one. I brought the whole thing out to the car and slid it into place. Incredibly, it fits! However, it is going to be a real challenge to ensure that all the gaps in the ductwork are closed off from the console. Once it's in place, you can't really tell where the gaps are or aren't. Maybe a flashlight in there and I'll check for light leakage.

Anyhow, that's a task for another day. I came back to the workshop and began work on the lower ductwork to vent the exhaust into the dash. I got all the pieces cut out and they are glued together and drying now.

A little more fabrication, basically in getting the ductwork to line up. The "***** around factor" is pretty high there and I'll burn a lot of time trying to get it to work, but that will be most of the fabrication.

I also had an idea about how to fix my P1900 switch problem. I think I'll get two springs out of some ballpoint pens and solder wires to them. I'll put them side by side and drill small holes for them in the back of the dock. On the Mini, I'll put two metal circles and solder wires to them. The circles will line up with the springs. When the unit is docked, the springs will press against the circles and should complete the circuit.

tj!2k4 · 06-12-2005, 08:57 PM

You could try some thin foam padding between the ductwork and the console to make sure that you get a more-or-less airtight seal..

Bugbyte · 06-12-2005, 09:20 PM

That's exactly what I was thinking. Do you know of a likely place to look for it? Would an auto parts store be a good place to look? Otherwise, I was going to try a craft store.

tj!2k4 · 06-13-2005, 08:50 AM

Probably the craft store.. or.. a lot of times there is a thin sheet of padding included when you buy a motherboard (between the motherboard and the bottom of the box). You should be able trim that to make a gasket..

ScubaX · 06-13-2005, 11:18 AM

Great Stuff Pro spray foam. You can get it at Home Depot. I would leave you a link but all my trys to cut and paste a link just led me to what ever page Home Depot wanted me to go to.

Bugbyte · 06-13-2005, 12:24 PM

I've used Great Stuff before, around the house, but it dries to be sort of hard. Do they make a version that stays flexible?

ScubaX · 06-13-2005, 12:40 PM

Is this the kind of foam your looking for? eFoamstore

I have not heard of a spray foam that will dry soft such as the foam from eFoamstore.

bellerophon · 06-13-2005, 01:49 PM

Quote: Originally Posted by Bugbyte

I've used Great Stuff before, around the house, but it dries to be sort of hard. Do they make a version that stays flexible?

The window and door jamb great stuff dries much softer. Its made not to expand the jambs as much and allow for movement.

bellerophon · 06-13-2005, 01:50 PM

If you feel like driving to College Park, MD during the day or Upper Marlboro, MD during the afternoon I can give you some 1/8 or 1/4 inch one sided foam tape. Have tons of the stuff.

noizmonkey · 06-13-2005, 07:48 PM

have you thought about some dynaliner? www.dynamat.com

you could just apply it to the exterior of your plexi box, the thickness should fill all your gaps and it's heat resistant to about 225F

Bugbyte · 06-18-2005, 01:46 AM

I implemented the solution to the power wire problem that I sketched out a couple of posts ago.

I took two ballpoint pen springs and soldered wires to them. I drilled holes in the dock and embedded the springs in the dock. Then, I took two brass grommets that are used to mount radio controlled airplace servos and filled them with solder and a wire. I drilled a hole in the back of the Mini where the springs touch and then glued them in place on the Mini.

I soldered the power wire pigtail to the wires coming out of the grommets and was finished. I then docked the Mini and tested it for continuity with my voltmeter on both wires. It worked great!

I gotta say, I thought this was an inspired solution. Especially since I completely boneheadedly overlooked the problem to begin with. Here's some pics:

Here's the dock with the ballpoint pen springs mounted in it.

Oh yeah, I almost forgot. I drilled through the bottom of the plexiglas heat shield I built and tapped screws through it and ever so slightly into the bottom of each plug in the dock. That should keep them from coming out!

NeckPayne · 07-05-2005, 06:06 PM

I read your post on another thread...now I'm curious. Where you at? Looks pretty sweet so far!!

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