2004.5 Kia Spectra EX - CarPC / GPS / Sirius / TouchScreen

EagleTG · 02-15-2007, 05:05 PM

--==*> UPDATE 03-Sep-2007 -=- Final installation pictures posted!!! See my post in the "Show off your project" forum or CLICK HERE! <*==---

---==*> UPDATE 17-Aug-2007 -=- FIRST IN-CAR BOOT! See post #15 or CLICK HERE! <*==---

I've been working on this one for a while. I'm just getting around to taking some pictures, and posting them here.

The scope of the project includes GPS, Sirius Satellite Radio, MP3/Audio, Video and more. All based on an EPIA Mini-ITX M10000-II Via motherboard, and controlled completely by a Xenarc 700TS touch screen. This will be fabricated into the dash on my 2004.5 (same as 2005 and 2006) Kia Spectra EX.

I'm powering the system with an M2-ATX power supply. I'll use the pictured Zippy keyboard (got it at a computer show) and the pictured wireless mouse when I need something beyond the touch screen. These items will be stowed in the center console and will be connected to USB ports that I mount near the center console when needed. These USB Ports will be connected to a USB hub and have a single USB cable running to the trunk. This same panel with the USB ports will also house an Auxiliary-Input, power switch, and MAYBE a reset button. I plan on trying to hide this panel under the center console arm rest.

I plan to power the monitor from the M2-ATX, so we'll see how that works out. It's another set of wires that I need to run from the front to the back, but should work OK.

The computer itself, Sirius satellite (with MitchJS integration module), and another USB hub will be in the trunk. I will run the GPS receiver and USB WiFi module to the rear speaker deck. I plan on making a little "carpeted" box/cover to hide them. The box/cover will be made of wood so it is mostly radio transparent.

I'm toying with using a relay for the master power switch circuit, so I can run thinner wiring to the actual switch in the center console, and keep the thicker wiring running mostly straight down the side of the car. I'm still working on the details of my wire map. I want to have it all planned out, because if I don't, I know I will forget something when I'm doing the install (and then have to tear everything apart again).

In the first two pictures, you can see the complete system (and all the horrible wiring) set up in the house for configuration and testing.

In the following picture, you can see the outside of my Ikea Karbo key cabinet modified into a small form factor computer case. You can see the circle of scratches from when my hole-saw slipped/skipped.

You can also see the 4 screws used for mounting the hard drive to the lid.

Inside view of my CarPC. You'll note the IDE cable runs under the motherboard, and a 90 degree and 45 degree compound fold creates a nice flex-point for opening and closing the case. This fold took FOREVER to get right.

A closer view of the internal wiring, power supply, and fancy fold in the IDE cable. The ATX power wire has a twist that keeps the wires together while giving it the proper natural bend to keep it in the channel between the motherboard and power supply board.

Another shot of the guts. You can see the cut-out for the ports, and also the inside part of the tension/friction snap/latch that keeps the thing shut.

Another view of the IDE cabling and power wiring for the hard drive.

Below, you can see how gracefully the IDE cable bends when you are closing the case.

Another view of the bending IDE cable. In the below view, the case is just about closed.

A view of the bottom side of the Ikea Karbo key cabinet. You can see the large rubber feet, and some of the mounting screws/nuts. You can't see them in this view, but there are lock-washers under the nuts. I cut the stamped-metal key hooks completely out of the cabinet instead of bending them back. I figured this would keep the bottom flatter. Through the key hook holes, you can see a rubber car floormat that I modified to prevent shorts against any exposed metal.

Screw-locking CB Microphone plug (RadioShack) that I'm using for the power connection. I have one conductor as switched 12v, one as constant 12v, and one as the negative/ground. The original Molex connector I used was TERRIBLE. This one is an amazing improvement.

It's apparent from the pictures that I seriously need to invest in some compressed air. :-D

I've recently scored (eBay) a replacement dash surround for my car, so I'll be able to begin my fabrication shortly. I wanted a spare before I started. I have to drive this car every day, so this way I can have one in the car, and one on the workbench. I plan on keeping it OEM looking.

I know there's some stuff that I forgot to mention, so I will add more to this thread as time goes on.

----- Added 9:08 pm 15-Feb-2007 -----

Here's the mounting setup that I used to mount the motherboard and the power supply board.

Dennis5587 · 02-15-2007, 06:35 PM

NICE BEND IN THE RIBBON CABLE!!! it looks AMAZING!!!

...nice case as well

EagleTG · 02-15-2007, 06:42 PM

Quote: Originally Posted by Dennis5587

NICE BEND IN THE RIBBON CABLE!!! it looks AMAZING!!!

Haha, I know it sounds stupid, but I had wrestled with the positioning/routing of that cable forever. I was so relieved when I finally got it working the way I wanted. I wanted to show the world the prowess of my IDE folding abilities.

treetop777 · 02-15-2007, 06:48 PM

Nice! One case fan..is that enough you think?

EagleTG · 02-15-2007, 07:13 PM

Quote: Originally Posted by treetop777

Nice! One case fan..is that enough you think?

In my testing, it runs completely cool. I've left it on for 8+ hours straight (way more than I'm ever in the car at a shot). All internal components were cool as a cucumber. Now, during the summer months, who knows. The fan really moves a lot of air, it's surprising. My theory was that the power supply board doesn't seem to generate much heat. The motherboard is only using one fan, and that fan is much smaller (and moves less air) than the one I installed on the case. So as long as I'm moving at least as much air as the heatsink fan on the motherboard, I'm guessing I should be OK.

I guess we'll see.

treetop777 · 02-16-2007, 04:01 PM

OK. seams like you did give it some thoght. Again, that's a nice case..you pretty proud of that fold ha!

EagleTG · 02-16-2007, 11:41 PM

Quote: Originally Posted by treetop777

you pretty proud of that fold ha!

The fold > the entire project. The fold is all encompassing. Enter the fold. Er... Fray... Enter the fray.

EagleTG · 07-23-2007, 01:41 PM

Update! Made some huge progress over the past few months. I got all of the wiring completed (nothing interesting to photograph there). I also got the head unit/radio repositioned into the center/floor console instead of where it was in the dash. I was considering going head-less, but couldn't quite come up with a decision, so I decided to keep it in the mix. I didn't grab pictures of the repositioning yet, as it's still in need of some "prettying".

I did, however, grab some pictures of my progress in fabbing the dash piece. In hindsight, a photo would have helped... So here's one I snagged off eBay.

Here's my current state:

Primered (spray putty) way beyond where I needed it so I can feather the edge to smooth it out. I will be using trim paint.

Coming along... slowly...

EagleTG · 07-29-2007, 09:57 PM

Here's the dash part painted. I sanded a bunch more (including all the way through the spray putty in spots) in order to use some Bondo Glazing Putty. Re-spray puttied, then used some Dupli-Color Trim Paint (which kicks ***). I'm very pleased with how it turned out.

kickercivic1 · 07-30-2007, 07:57 PM

That dash turned out great. Goood job... Just a question about of blue, that fan on the case is the air blowing in or out??

Dennis5587 · 07-30-2007, 09:35 PM

yeah, that dash looks good, lets see it in the car

EagleTG · 08-03-2007, 09:06 PM

Quote: Originally Posted by Dennis5587

yeah, that dash looks good, lets see it in the car

Patience, grasshopper... Patience. :-D

EagleTG · 08-03-2007, 09:08 PM

Test fitting everything... Picture below. I've got one more modification to make to this dash piece. I want to fit the rear defrost/defog button and the hazard buttons into the same area where the existing hazard button is. Going to start working on that tonight.

EagleTG · 08-03-2007, 09:11 PM

Quote: Originally Posted by kickercivic1

Just a question about of blue, that fan on the case is the air blowing in or out??

The plan is to have it blowing out, from the pics it looks like that's how I have it but you have me second guessing myself. Heheh. I'm not entirely sure that this will be enough, but I tested for a six hour road trip and it wasn't even warm. I also tested in the house for extended hours while running some processor stress tests. Seems like it's OK. It's a super loud 60mm fan, so I'm glad the thing will be in the trunk.

UPDATE: I verified that the fan on the processor is blowing out/up, as is the external case fan. Both blowing in the same direction should work well, and they are a bit off-set, so there should be some decent flow through the case.

EagleTG · 08-17-2007, 09:19 PM

WOOOOHOOOO!!!! FIRST BOOT (IN CAR)!!!!

Still just a little clean up and detail work to do. This was the first test of the complete setup in the car.

It'll be "done" tomorrow. I'm sure little stuff will be changed here and there. I'll take better pictures in the daylight tomorrow, and share with you all. (I also need to clean the car before the pics.)