There are a few servers that are too old. There is a need for a few more servers to get a room level redundancy. These things can be expensive.
As I’m cheap, I’ve been using older servers that accept 3.5″ disk drives. Some except 2 drives, some 6, some could accept more, but the case doesn’t.
The fix I chose was to move to some four bay NAS enclosures. This is a reasonable size that balances with the network I/O capability.
These enclosures all take the Mini-ITX motherboard.
These motherboards are nothing short of amazing. In the middle tier, they have all the things a full-size motherboard has. Some have 4 memory slots, some only 2. They come with 1, 2, 4 Ethernet ports. Some have SFP ports. Some have SATA ports. The number of SATA ports ranges from 1 to 6. Some come with PCIe slots.
Depending on what your needs are, there is a motherboard for you.
Since this was going to be a NAS, the motherboard I selected had to have 4 SATA ports, an NVMe slot, and SFP+.
Yep, this exists. They don’t exist at the price point I wanted to pay. It finally clicked with me. I can just put an SFP+ PCIe card into the machine.
Thus, I picked a motherboard with 4 SATA, 1 Ethernet, 1 USB3, 1 PCIe slot, enough memory and 2 M.2 slots.
Some NAS enclosures do not have the opening for a PCI slot, so it was important to pick a case that had the card opening.
When I got the enclosure I was impressed.
It is a sturdy, thick steel case. There is no plastic on the entire thing. There are for hot swap disk bays plus mounting space for 2 2.5″ drives. Exactly what I was looking for.
When I went to install the motherboard, I was shocked to find that the CPU cooler didn’t fit. I ordered a low profile. I’m impressed with that as well.
I get the board mounted. It looks nice. I go to close the case and the cover won’t fit on. The cover has a folded U channel that goes over the bottom rail of the case to lock the case closed.
The problem is that there isn’t enough space between the edge of the motherboard and the bottom rail for the U channel to fit.
My first real use of the right-angle die grinder. I don’t have a cut-off wheel for it, so I just ground the edge away and it worked.
Of course, I gave myself a frost burn because I was too busy to put gloves on to handle the die grinder.
Back to the worktable, the cover now goes on. I plug a wireless USB dongle into the USB 3.0 and boot. Nothing.
It took me a couple of days before I figured it out. The case came with no documentation. The front panel connector has both a USB 3 plug and a USB 3 plug. I plugged both in. You are only supposed to plug in one. Fixed.
The installation happens, I’m happy. It is fast enough, it is responsive enough. I just need to get it put in place with the fiber configured.
I take the cover off the back slot. Go to put the PCI card in.
The (many bad words) slot does not line up with the opening in the back of the case.
The open in the back is off by 0.8 inches.
I consider cutting another card opening in the back. That won’t work. The card would be half out of the side of the case.
I ordered the cutoff wheels for the die grinder, I know I’m going to need them.
I decided to cut the back opening wider. This will leave an opening that can be taped closed on the PCI side. It allows me to use the existing slot with retaining hardware. I good idea.
All I need to do is unscrew the standoffs, drill and tap four holes in the right place, and I’m done.
Except… Those standoffs are pressed into place. They don’t unscrew.
No problem. I have a set of standoffs. I’ll just cut the existing standoffs off. Drill and tap holes in the right place and use my standoffs.
Except… My standoffs are the normal length. These standoffs are a custom length. I can’t do that.
Tools to the rescue
First stop, the arbor press. It is a small 2 ton press. I have no problems pushing out the standoffs. The press also removes the bulge from removing the standoffs.
Next step, the milling machine. Using the gage pins, I found the size of the holes is 0.197-0.198. Measuring the standoffs, I get 0.208. I settled on 0.201 for the hole size. I should have gone a 64th smaller.
There is no way to clamp this thing in the vise. I do have strap clamps. The case is quickly put into position.
The first hold is located, then drilled. No issues.
Except I don’t have enough travel to reach the other three holes. I reposition the case on the table and go for it.
I go back to the arbor press to put the standoffs back in. I don’t have enough height to support the case while installing the standoffs.
Back to the mill. Square to ends of a hunk of aluminum. Punch a 3/8in hole in it. Work on the mill vise and get the standoffs put back in place.
In the middle of this, I have an alarm, fearing that I put the standoffs in the wrong place. I do a quick test fit and everything is perfect.
It takes me a good hour to put the case back together with all the case mods done. It looks good. I’m happy with how it came out.
Today is search day. I have to find the 8 meter OM-4 fiber for this NAS, and I have to find the box of screws that came with the case for the hard drives. Once I have those, this can go into production.
I know what to look for on NAS cases. I’ll be building out a few more of these boxes over the coming months. First to replace two boxes which are too old. One for the redundancy.
The world will be good, or I’ll punch it again and again until it is good.
P.S. This is filler, the article about Trump’s win in the D.C. District court was taking to long.