With the newly polished case, I needed to figure out a way to attach the plexiglass. I didn’t want to use liquid nail, as I wanted a more permanent option. I had thought about chrome screws, spiked screws, etc.
My father recommended I use rivets. I have always loved how rivets look, so I jumped on that idea. Some people warned me about the possibility of the plexi cracking, but my father guaranteed I shouldn’t have any problems.
We first drilled pilot holes through the aluminum, then on the plexi where the rivets would go. The rivets popped into place without any problems. The hold the plexi in place as good as anything else. Because the rivets are aluminum, I pulled out the Mother’s, and polished them up so they match the case perfectly.
At the same time I was attaching the case, I was working on a better way to light the etching. I bought some 3mm UV LEDs and decided to get to work. At first, I wanted to put a total of ten LEDs around the etch. Three on the top and bottom, and two on the sides. After mocking it all up, it was total overkill to put the three on the bottom, so I opted to go with a total of seven LEDs. They would go three on the top, and two on each side.
I drilled small ruts on the plexiglass so the LEDs would fit flush “inside” the plexiglass itself. I then wired the LEDs up in parallel with corresponding resistors after each LED. I then used a hot glue gun to hold them in place, and made sure I had some masking tape under the bare LED leads as a precaution, just to make sure nothing shorts out. I wired up a standard Molex connector with long enough wire, so it would be simple to remove the case when needed.
The original Plexi front cover that comes with the SK41G has a rather ugly, puke green stripe that I wanted to remove. I had some Bluemagic “Plastic & Plexiglass cleaner” laying around, so I removed the cover, and lightly sanded the green stripe down with a “fine” brillo pad (didn’t have anymore sandpaper) and buffed it with the Bluemagic compound. It worked out beautifully, and now there is no more stripe.
The last thing I did to this shuttle box was remove the original honeycomb mesh grille in the back of the case. Instead of making a mess with a dremel, and thus having to remove all of the components, I got a nice set of wire cutters, and cut the mesh. It came out very nice, and seemed to help airflow a bit.
So what does the whole thing look like? Here it is: