Category Archives: Woodworking

A Warm Antique Brown Finish for Pine


I make a lot of things from pine as hard woods like oak are crazy expensive where I live. It’s fine for things like the set of small drawers pictured above. The problem I used to have with pine was achieving the Arts and Crafts style warm reddish-brown finish that I like. Dyes give patchy results on soft wood like pine, so I have been experimenting a lot with pigment stains. A particular favourite of mine is a reddish-brown colour called “traditional cedar” (a Wattyl Colourwood stain). I usually combine it with a small amount of another very dark brown (almost black) stain (Wattyl Colourwood “terra”) in order to achieve a rich dark brown. For durability I usually finish with a couple of coats of polyurethane. That gives an OK finish, but pine is a very white wood and the stained colour lacks the depth and amber warmth of an antique Arts and Crafts finish. Also, polyurethane can be very difficult to apply without getting dust nibs or runs or missed patches, and tends to give a bit of a plastic look to the finish. It’s great where you need durability though, such a the towel cupboard I made where people are likely to touch the wood with wet hands.

Recently, however, I discovered shellac. Of course I knew about shellac, but had never used it. Suddenly I was able to achieve the finish I wanted on pine. The key to the finish is amber shellac. It affords a lovely amber warmth to the finish, complimenting the red-brown stain. Now I know heaps of woodworkers will already be familiar with shellac and probably have their own preferred way of using it, but for those that are new to it here’s how I achieved the finish on the drawers in the photo above.


The first step is to sand the wood down to 180 grit with sand paper.


These are the pigment stains I use. “Traditional cedar” on the left, and “Terra” on the right. For the drawers I used a mixture of about 4 parts trad cedar and 1 part terra.


The stain mix is wiped on with a rag to give a nice dark reddish-brown (I think I’ve used too much terra in this test piece, more like 3:1).


Once the stain is dry, I apply a coat of amber shellac with a brush. You can see the instant warmth it adds.


I buy pre-made shellac. It comes in both amber and clear. Being dissolved in ethanol, it dries very fast and can be tricky to apply with a brush over large areas, especially if the air is warm. You have to work quickly, but build-ups from overlaps can be sanded back later.


When the first coat of shellac is dry (after one or two hours), I rub the surface with #0000 steel wool. You have to be careful at this stage or you’ll rub through the shellac and remove the stain. Difficult to fix.

I don’t have a good picture of the next step, but after the steel wool I rub on and wipe off a “glaze” of the dark Terra stain. Not much actually sticks, but it does make a difference and helps to give it a more aged look.


Once the glaze is dry, I apply two coats of the clear shellac with a brush to build up some depth. You only have to wait about an hour between coats, but after the second coat I leave the shellac overnight to dry and harden properly.


With the shellac properly dry I use some #000 or #0000 steel wool to sand the surface smooth (if it’s really rough I might even start with some 600-800 grit paper). I have done this step dry, but in this photo I’m using Danish Oil to lubricate the job (wipe it all off before it starts to dry). Here I am rubbing in circles to help reduce the fine ridges created by brushing the shellac. After this I rub the steel wool with the grain to remove the circular scratches (it doesn’t take much work). Finally, I finish the sanding with #0000 steel wool to give a smooth dull finish (like the third photo above).

The last part of the finish is to apply three coats of Danish Oil. This fills the surface and creates a beautiful shine which is not too glossy. I like Danish oil as it dries quite fast so you can build up the finish quickly.


And here it is with the Danish oil applied.

More Photos of iPad Stand Construction

After the success of my original iPad stand I decided to use the left-over length of oak board to make four more stands. I slightly modified the design this time to include an angled front face on the base. I am calling this design “iPad stand No. 3”, as it is the third modification to my basic stand design (there was an original prototype with a shorter upright, as well as the design described in my earlier post). I decided to photograph the construction of these stands and write another post as I felt my previous post was lacking in photos and might have been hard to follow. So here again is a description of how to make my stand for the iPad 2.

Note: measurements below for the iPad 2 only.

As before I started with a board that was 110mm wide by 22mm thick after squaring and milling (the same board in fact). From this I cut four base blocks, this time 110mm long to match the width of the board (the length should exactly match the width of the board). Making them 110mm long meant I could use the full width of the board for the upright parts.


The four 110x110mm base blocks.

The next job was to cut a slot 14mm wide by 5mm deep in each block. The slot is cut 20mm in from the front edge of the base as indicated in the diagram below.

vanishing pt test


This is my simple home made router table. An acrylic plate screws onto the base of the router and sits in a recess in the table.


The slot is cut in one of the bases. I made the slot in two passes as my biggest router bit was 12mm diameter.

After cutting the slot, mark a line along the bottom of the slot, 9.5mm (can be a small as 9.1mm) in from the front edge of the slot.


I found a stick that was 9mm wide and used that to measure out the cutting line in the slot.

Next, mark a cutting line for the front face of the base. This should be located 8mm from the slot front as shown in the diagram below. Ultimately you’ll make four angled cuts in the base as indicated by the blue dashed lines.

vanishing pt test 2


Set your saw blade angle to 14°. The rest of the cuts will be made at this angle. Start by cutting the angled front face of the base. Keep the off-cut as you’ll need it for the glue-up.


The front face cuts have been made.

Next make the cut in the slot to create the front piece of the base.


Lining up the saw for the slot cut.


The photo above shows a narrow piece I used for testing the cuts. Here the slot cut has been made and you can see that small bit of the slot remains on the back bit of the base. The next task is to trim that face to remove the residual slot.

Now mark another cutting line on the top face of the bask part of the base, 60mm from the sloping face as shown in the cutting diagram above. Cut along this line to create the rear sloping face (at the opposite slope to the front face). Keep the off-cut.


The parts of your base block should now look like this.

Next, I took a length of my 110x22mm board and cut it through the middle of the 22mm side on a table saw to create two thinner 110mm wide boards for the upright parts. These I milled to about 7.5mm thick. These were then cut into 160mm lengths with the saw blade still at the 14° angle (same slope direction at both ends).


Cutting a 160mm upright piece from the thin board.

Before gluing the parts together, sand the upright board to 180 grit, and also sand the slot in the base, and the top face of the rear part of the base. These surfaces are difficult to sand properly once glued.

The final construction job is to glue the upright board to the base parts. To do this, make a sandwich of the base parts, including the off-cuts (front and back, don’t glue these of course, just glue the faces that butt against the upright) and the upright and clamp it tight between two lengths of timber as shown in the photo below. For glue I use cross-linking PVA.


When set, remove the clamps and discard the off-cuts. The stand is ready for final sanding and finishing.


Make Your Own iPad Stand


Percy admires the stand

UPDATE: I have added a new post with more construction photos and a slightly modified stand design here.

Here’s a simple woodworking project that I thought might be of interest to iPad owners . When I recently purchased my iPad 2 I decided to forego a “smart cover” in favour of a  leather sleeve from Saddleback Leather. To complement the sleeve I decided to whip up a wooden stand.  The design I came up with is easy to make with only three glued-together parts, as I describe below.

I made mine from white oak. Start by milling a two lengths of board, one to about 22mm thick (could be a bit thinner depending on what you have), the other to 7mm thick. I milled 300mm lengths of each as that’s about the minimum I can put through the thicknesser. The base part is made from the thicker board, and the upright from the 7mm board. The thicker board should be at least 110mm wide, and the thinner board should be cut to exactly 100mm wide.

Ultimately you want to end up with the three pieces, which have the following profile when the stand is viewed from the side. Note that the base pieces are being viewed end-grain on, so really their length is 100mm, not their width, but you know what I mean.

ipad stand plan

N.B. These measurements are for an iPad 2, NOT a first generation iPad. The width of the slot (9.5mm above) should be increased to 14mm for the original iPad.

These parts will be glued together to make the stand as shown below.


For the base parts, straight cut a 100mm length of the thick board. It should be exactly the same length as the width of the thin board. What I did was finish the thin board to 100mm wide first, then used that as a template to set the cut distance for the thick board. Now you should have a base block which is 100mm long, at least 110mm wide and 18-22mm thick.

The next job is to rout the 5mm deep slot in the base. I suggest doing this before you make the angled cut which divides the base into two pieces. Using a table router is easiest. Cut the slot along the grain of the block, 10mm in from the front edge. Cut the slot about 14mm wide (18mm for iPad 1). This allows room to get the saw blade in for the angled cut. Mark a cutting line on the base of the slot 9.5mm (iPad 2) or 14mm (iPad 1) in from the front of the slot. Set the blade angle of your compound mitre saw to 14° and cut along the cutting line to make the front piece off the base. Make sure you’re cutting the angle the right way. The corresponding angled edge on the back part of the base will have some left-over slot cut in it, so trim it off using the angled saw. Now flick the back part around and cut the rear face at the same angle so that the long edge is about 70mm as shown in the drawing above. Keep the off-cut, as you’ll need it for the glue-up.

Lastly, with the saw still set at 14°, cut the thin upright board to length (165mm). Pre-sand the parts prior to gluing.

To glue the parts I sandwiched them between two lengths of wood as shown in the picture below. This is where you need to put the off-cut from the back of the base into the sandwich (don’t glue it of course) in order to make a vertical surface at the back.


Finish the stand as you please. I went for a dark warm-brown finish using a reddish dye followed by a mix of red-brown stain and a dark brown stain sealed with amber shellac and finished with satin polyurethane.




A Quick Wooden Computer Case


I recently decided to build a wooden computer case, despite the fact that I’ve never really liked wooden computer cases. The project came about because I realised that I had enough spare computer parts in my cupboard to build a reasonable computer. I don’t have room for another computer in the house, so I decided to build one for the garage. The plan was to make the computer as cheaply as possible from spares; the problem was I didn’t have a case to put it in. I thought about buying a cheap case, but in the end decided that since it was only for the garage I would whip one up out of plywood.  So that’s what I did. It’s not a particularly interesting project, it’s a simple wooden case with fairly boring parts inside, but I thought I’d put up a few pictures and notes anyway in the hope they may be of interest to others who may be thinking about building a wooden case.

I made the case from 12mm thick plywood. I went looking for a sheet of the usual pine ply, but was talked into an even cheaper sheet of poplar ply with hardwood veneer. I wondered about the quality of the ply (rightly so as it turned out), but bought it anyway. The problem with the ply was that the veneer is about 0.1mm thick and chips and flakes off with the making of every cut and hole. In addition, most cut edges (which I had planned to leave exposed) have gaps where there are missing bits in the laminated layers. It would probably be fine for making a door panel fitted in a frame, but was not a great choice for this project. I ended up covering the edges and using a dark stain to hide the chipped veneer, which worked out reasonably well.


Here I’ve cut the side on which the motherboard is mounted. I’ve added another square of 6mm ply under the motherboard in order to lift it up a bit more. This moved the cut-out for the connector plate further away from the edge of the back board, making it easier to cut. The block of wood beneath the motherboard is a spacer for the power supply, also used to move it away from the side.



As I did with the server cabinet, I used small rubber grommets as stand-offs and screwed the board down to the plywood.



There were a number of slots to cut, all of which I did with a router using wooden templates and a template guide on the router. This is the slot for the connector plate. I was able to use plywood offcuts to make templates since the perfect template thickness for my router guide is 12mm. You can see in the photo that for square or rectangular holes like this I just mark out the hole size with template offset added (two times the distance between the edge of the the template guide and the edge of the router bit), and then plunge cut the hole in the template with my drop saw. It’s quick and easy and makes a perfect square (or rectangle). The fact that the cuts extend beyond the bounds of the hole does not matter. Because I’m cutting right through the board here, I’ve placed another sheet of scrap ply underneath to stop the router cutting the table. I recommend making several shallow cuts, as cutting the full 12mm all at once is too much for the router.



And here’s the back of the case with all slots cut. I try and make very careful measurements (vernier calipers are indispensible for projects like this), but even so, the perfectly snug fit of the metal connector plate was a pleasant surprise. You can see that the router bit leaves rounded corners. These can be squared with a chisel, but I just left them as they were. The large hole is for the power supply, which will sit at the bottom of the case. It seemed easier to put it at the bottom rather than have to construct a sturdy shelf at the top, however it does make cooling more of a challenge.



This photo shows the PSU cut-out from the back. The PSU hole has a recess on the inside into which the PSU fits. This helps secure it. To cut the recess, I made a template to cut the exact outside size of the PSU when using a 12mm router bit. I then cut the through hole with a 6mm bit, which made it 6mm smaller than the PSU in each direction. Keeping the template in place, I switched to the 12mm bit and cut the recess to a depth of 7mm.



In this photo I’ve glued the back and base to the side and temporarily installed the motherboard to assist with positioning the hard drive and PSU. I only intend using the one hard drive, which is held in place with a simple friction restraint (a “Z” shaped metal bracket screwed to the base board). The drive sits on a rubber pad to reduce vibration, and will eventually be earthed to the motherboard with a wire.

I guess I should say something about the hardware. The mother board is an Intel D975XBX2, A.K.A  “Bad Axe 2”. I actually won it in a computer mag competition, along with some other parts. I used it for a while in a computer, and found it to be a difficult board to overclock, although stable at the right settings. The processor is a Core 2 Duo E6600, one of the original Core 2’s. The first Core 2 I bought was an E6600, but I later sold it. The only piece of hardware I didn’t have for this build was the CPU, and CPUs compatible with this board can no longer be purchased new. I found a reasonably priced E6600 on an auction site. The guy even threw in the custom “Freezer Pro” cooler, which I don’t think is a great cooler, but probably better than the stock job (I’m a big fan of the Thermalright ultra-120 extreme CPU coolers). My preferred hard drive brand is Western Digital, and luckily I had a spare WD 500GB drive for the build. Most of my data is stored on my home server, so my client computers only need one modest drive. With regard to drives, I decided to go all futuristic and not include an optical drive. Actually, it’s probably more that I wanted to keep the case as simple and compact as possible. It isn’t as hard to cope without an optical drive as you might imagine. I now buy and download most software and music etc. from the internet, and software on DVDs can easily be transferred to a USB flash drive on another computer. That’s how I installed Windows 7 on this machine. The graphics card, not installed in the photo above, is an Nvidia 8800GT with a nice quiet aftermarket cooler.



I spent a while thinking about how to fit ventilation fans to the case. Because the computer will be operated in a potentially dusty environment I did not want the case to be under negative pressure. I decided that two 12cm intake fans would do the job, one on the top feeding air to the CPU cooler and RAM, and one at the front blowing across the hard drive. The fans would need  filters which could be removed from the outside, as this case will not be as easy to open up as a metal one. My solution was to cut an 110mm diameter circular hole with a jigsaw, then rout two recesses on the outside face. The first recess was a circular 130mm recess centred over the hole and cut to a depth of 8mm. The second was a 134mm square recess centred over the hole and cut to a depth of 6mm. The result is shown above. To make a grill to retain the filter cloth, I cut the bottom out of a small garden sieve and trimmed it to fit into the circular recess. This is held in place with some hot melt glue. I then positioned the fan over the hole and marked, drilled and countersunk the holes for the fan retaining bolts. I chose bolts with countersunk heads so that they would be flush on the outside. Over all this went a square of filter cloth (vacuum cleaner motor filter), cut to fit into the square recess.



Finally, I made a removable wooden grill from some 5mm think strips of pine. The grill was sized to fit into the square recess, and was screwed down over the cloth with four pan head screws as shown. The panel on the left is the front panel, the other is the top panel. On the front panel you can see that I’ve also drilled out a 16mm hole for the power switch, and above that a 3mm hole for the power LED. The thread on the power switch was not long enough to go through 12mm of ply, so I recessed an area behind the switch hole with the router.



In this photo it’s all starting to come together. I’ve fitted all parts, installed Win 7, and am testing the system stability with Prime 95 whilst monitoring temperatures with Everest (two invaluable programs for the computer builder). You can see the little white power LED above the switch. As well as the left side of the case, I decided to also make the top panel removable. This makes it easier to replace the top fan, and to remove the motherboard. To secure the top panel, I screwed it to a wooden rail which I glued near the top of the three fixed sides. The removable side panel also has a wooden rail glued around the inside. Three of the top screws (missing in the above photo) screw into the side panel’s rail, helping holding the side on. I decided to make more of a decorative feature of the screws by using cup washers.



There are a couple of things to note about the back. Firstly, you’ll notice the wooden plug in the end of the video card slot. I had to make these slots a certain length in order to be able install and remove the cards. The metal return on the card bracket sits on the edge of the ply, which stops the card from rotating downwards. However, because of the slot length, when you plug in the cable, the pushing tends to rotate the card out of its slot. To stop this I made a tight fitting removable plug. The second thing to notice is the aluminium strip screwed over the lower slot. Ultimately the slot above it got one of these too (note: the blue light is from LEDS on the front fan – not intentional, it’s just that I had this fan going spare). I cut these two slots because among my spare parts I had a WiFi card and a Creative Audigy sound card. Once I got the thing powered up I quickly learnt several things: Firstly, useful WiFi reception was not available in the garage, secondly the WiFi card was not compatible with Win 7, and thirdly, despite Creative’s Win 7 drivers, the Audigy card did not work at all well with Win 7. Ultimately I decided to extend wired LAN to the garage, and use the motherboard’s built in sound chip (at least for now). The slots were thus superfluous, and were covered up.



Another shot of the back. Here you can see the small white reset switch. I installed it into a recess so that it is flush with the back. I hoped that this would help avoid accidental pushes.



This photo shows two more modifications. Firstly, I found that things were a bit warm because hot air could not easily escape the top of the case. There’s a reason why most cases have the PSU at the top. The solution was to cut some top vent holes in the removable side. These have some mesh behind them to discourage spiders. Secondly, I found that the removable side needed to be held in by screws at the front and back as well as top and bottom. The wood had a tendency to bow out otherwise. I thus added a row of screws down the front and back. The back and underside screws are just normal countersunk screws.



Then I decided that the exposed plywood edges were just too shabby, and milled some thin strips of pine to glue over them, which is what’s happening in this photo. I didn’t bother with the edges at the back.



And so to finishing the case. I had to strip everything out again in order to sand, stain and varnish the case. I started with this light brown stain, but ultimately decided to go for a dark brown finish, better to cover up the veneer chips.



Here’s a shot of the case inside. You can see the wooden rail below the top edge. I’ve also added another strip down the front inside to take the decorative front screws.



And here’s the inside with everything refitted and ready to go. Notice the wooden stop screwed in behind the PSU to stop it from moving backwards. The PSU hold down “Z” bracket is screwed into this stop.



Finally, the end result. Stained dark brown and finished with four coats of polyurethane. I must say that it ended up looking better than I imagined.

The HP monitor is one I repaired.  One day after a few years of use it started smoking alarmingly. I wrote it off as dead, but didn’t throw it out. Eventually I did some research, and with a few dollars worth of parts ordered online, and advice from folks on the Badcaps forum, was able to replace the burnt out transistors and get it working again. Brilliant. Now all I have to do is clean out my messy garage so that I have somewhere to put it!

Building a Windows Home Server – Craftsman Style, Part 3

Setting Up the Server

When I left off in Part 2, the cabinet was built, and the server had been assembled. The next step was to move it inside and install the Windows Home Server operating system.

In this photo, the cabinet is in place next to its existing buddy. Now my two desktop computers, along with the ADSL modem and gigabit router, are located on a desk on the opposite side of this office area. Since WHS must be wired to the network, and I didn’t want an ethernet cable running across the floor, I had to run a cable through the wall. Luckily the exterior of this wall has removable corrugated iron cladding. Removing and replacing it was a slightly stressful job, but worth it for the end result. I used Cat 5e cable for the run, as it was all I could buy by the metre. For some reason, Cat 6 cable was only available in 300m drums, slightly more than I required. Cat 5e is rated for gigabit ethernet, so no problem.

To install WHS, I put the drawer assembly on my computer desk and connected it to one of my monitors, and a borrowed keyboard and mouse. I attached a spare DVD drive I had in the cupboard with an IDE cable, and connected up the power supply. Now it was time for that magic moment that only happens once in a new computer build, first power up. I pushed the button. My blue power light came on, the drive spun up, the fans started and the monitor came to life. I pressed the DEL key to enter the BIOS to set up some initial parameters, ensured that the DVD and hard drive were recognized, and set the DVD drive as the first boot device. With every thing looking good, I put in the WHS installation DVD and rebooted. Then a problem. The Windows installer would start to load files, then quit with a read error. I checked the settings, checked the DVD drive setup, but still the same result. So I ripped a DVD burner out of one of my desktops and hooked that up. Installation proceeded normally, phew. But wait, what’s this, another error? This time, after its first reboot it gave a hard drive error. I had noticed the “press F6 to install third party drivers” message, and realized straight away what was wrong. Having been spoiled by Windows Vista, I had set the hard drive controller to run in AHCI mode and just expected the operating system to install. But WHS is based on Server 2003, and like Windows XP, requires AHCI drivers to be installed from a floppy disk at the F6 prompt (Note: I never checked it out at the time, but if your motherboard supports it, you may be able to set the BIOS to emulate a floppy using a flash drive). I considered just setting it to IDE emulation in the BIOS, but decided that was too easy (and requires foregoing hot swapping, NCQ and SATA 3Gb/s interface). I had a floppy drive, used perhaps twice in its life for the XP installations, so I plugged it in and hunted around for a disk. The only disks I could find were two I had used as “F6” disks before. I downloaded the F6 floppy utility from the Intel website, plugged the drive into one of my desktops and made a new F6 floppy. Then back to the server, which promptly gave a floppy read error. Anyway, to cut a long story short, both disks turned out to be dodgy (just too old). I eventually found one that worked at my wife’s work place. Once these problems were sorted, the installation proceeded smoothly.

I was pleased to find that powered up, the server was very quiet, and inaudible once inside the cupboard with the door shut.

All powered up and running. The drawer is pulled out to access the power switch on the right hand side.

Installing and setting up the Connector software on my two PC’s was straightforward, and I soon had both computers backed up to the server for the first time. This first backup can take a while, but the daily incremental backups are fast.

Initially, because I was having a problem with a computer that would not sleep properly (see my post on “The Computer that Wouldn’t Sleep), and because I didn’t want to leave the computer on all night, I would turn the server on first thing in the morning, then turn the computers on and let the server back them up. This prompted me to finally solve the computer sleep problem. Now I leave the computers in an S3 sleep state over night, and let the server wake them early in the morning for a backup. To save even more power, I turn the server when I’m finished for the night, and have it turn itself on at 6am using the Wake on RTC Alarm function in the BIOS (as an aside, I really liked the Gigabyte board’s BIOS, it has much better explanations of the settings than the ASUS motherboards I’ve used).

So my overall impression of WHS so far? Well, I think it’s an excellent and very useful product. It’s a great shame its reputation was tarnished by that tricky data corruption bug, but hopefully Power Pack 1 will finally see an end to that. I was never as diligent as I should have been about backing up data, but now it’s automatically taken care of. And when we wanted to share a file between computers, we’d often copy it to a flash drive and hand it over! Now we just save it to the server, which feels just as fast as reading or writing to a different partition on your own hard drive, that’s how well it works over a gigabit network. And then there are the cool remote access features…but that’s enough from me.

I hope you’ve enjoyed reading about my experience, and maybe will be inspired to build your own server, if you haven’t already.

UPDATE: I’ve taken the final step and added the second hard drive, a Western Digital SE16 500GB model, and the installed Power Pack 2 release candidate. It’s all working well so far. To make room and keep things tidy I removed some of the unused cables from the power supply, terminating the cut ends with a 9-pin nylon connector so that I can used them in the future if necessary (d.i.y. cable management!).

Building a Windows Home Server – Craftsman Style, Part 2.

In part one of this series I described how my need for a new office cabinet, and my desire to build a Windows Home Server came together in a single project, the craftsman style home server.

With a cabinet design roughly sketched out on a piece of A4 refill, it was time to start cutting some wood. I’m not going to go into detail about the woodworking and cabinet building process, as this blog is mainly about the server. Suffice it to say that there wasn’t a lot of mortise an tenon jointing going on as I have neither a dado stack, nor a mortising chisel. The cabinet was largely constructed using concealed screws, with through dowels to strengthen the face and door frame. The following pictures will give you an idea.

Now my Belkin N1 Vision router might have a nice LCD display, but it doesn’t have a cutter head that spins at 24,000 rpm! In this shot the venerable De Walt 621 makes short work of cutting slots in the sides for the shelves. My wife’s doing the work here while I take the photo. Computers leave her cold, but she loves those power tools.

In this photo, the sides (pre-stained on the inside to make life easier) are attached to a face frame by screwing through concealed blocks into both the side and frame. Note that I have also attached strips under each shelf slot to both strengthen the shelves, and make ensure that the the sides, which are made from two edge glued boards, are held firmly together.

Here’s the frame for the door, waiting to have a plywood panel fitted. Around this time I also cut out the shelves from both 17 and 12mm plywood, and applied a 5mm pine veneer on the visible front edge of each shelf. The thicker ply was for the base, and lower two shelves (including the server shelf).

After fitting the server shelf to the cabinet, I was able to finally construct the server drawer. The slot in the upper left of the drawer front is for an acrylic insert, which will serve as a diffuser for the server power LED.

This picture shows the LED in place below the acrylic. The LED is a 3mm high intensity blue type. After I cut the slot for the acrylic, I drilled a 3mm hole down through the center of the bottom of the slot. I then drilled a larger hole into the back side of the drawer front, just below the slot, and far enough in so that I could access the 3mm hole (I squared the hole out with a chisel to allow flush fit of the LED into the 3mm hole). I fitted the LED to a lead, bent it at a right angle and fitted it up into the 3mm hole as can be seen above. The acrylic itself has roughly sanded edges to better diffuse the light.

This is the power switch, hidden just behind the front of the drawer and easily reached by opening the drawer a few centimeters. I didn’t bother with a reset switch, and so far I haven’t needed one.

Once the drawer was finished I was free to start setting up the server hardware. Here I have placed and screwed down the motherboard, after fitting the RAM and CPU. To mount the board I started by placing the board on the wood, then marking through the mounting holes with a pencil. I removed the board and drilled small guide holes for the screws. At first I wondered how I was going to give the underside of the board clearance from the drawer base, then, whilst browsing my local electronics shop (probably for switches or LEDs) I found a packet of small rubber grommets, about 8mm high with a 6mm hole in the middle. Perfect! I placed them over the holes I’d drilled, then sat the motherboard on them and screwed it down with stainless screws. This also met my requirement of mounting any part that could possibly transmit vibrations through to the woodwork on a rubber washer or pad.

You’ll also notice in the above photo, that I’ve used the stock CPU cooler. Early on I spent some time puzzling over CPU cooling, as I wanted the server to be as quiet as possible, and my previous experience with stock Intel coolers for higher end processors was that they were quite noisy, especially when running flat out. I thought I was going to need to buy an after-market low noise cooler, and went to some trouble considering the options and whether they’d fit into the drawer space available. Luckily I waited until the CPU turned up. I’d never bought a low power processor before, and when I opened it I was amused by the small cooler, about half the height of those I was used to. I plugged it into a spare 12V supply and was pleasantly surprised to find that even at full speed it was almost inaudible. Problem solved.

In this photo I’m test fitting the drawer to the cabinet in order to mark on the back where the cutouts for the power supply, LAN cable, and a drawer ventilation fan should go. The power supply is a 480W Enermax that I had spare. I would have rather had a lower rated supply with plug in cables, but I couldn’t justify the expense since this supply was available. What this supply does have is fans that can be turned down to run very quietly. As with all the parts, the supply is mounted on foam rubber pads.

I fitted a fan to the inside of the back board (mounted on foam rubber of course) to blow air into the drawer. The fan in the photo was my first attempt, a high volume Delta fan I had spare. I fitted a resistor in order to run it at 6V and reduce its noise. Once the server was running, I realized that this was still by far the noisiest component, and replaced it with a new silent Sythe 500rpm fan (I had also determined that only minimal ventilation was required).

The server build was completed by fitting the Samsung hard drive behind the power supply. I made some mounting brackets out of right angled metal brackets I found at the hardware store (they are actually “concealed perlin cleats”). They allow enough height for me to eventually add a second hard drive underneath the first, although at this stage that space is filled with the surplus power supply cables. I may have to eventually remove some cables from the power supply. The metal brackets are screwed through foam pads into the drawer base.

At this time I don’t intend to use the server with more than two drives (apart from perhaps an external drive used as a shared folder backup). By my calculation, two large drives will give me backup redundancy, plus plenty of storage, whilst keeping the noise, heat and power consumption to a minimum. If I did ever want to add more drives I would have to build them into the shelf above.

The cabinet and server are finally finished.

At the back of the cabinet, I added a filter holder over the fan inlet to reduce dust ingress. The hole next to the filter is for the LAN cable.

And here it is, ready to take its place inside. The next task will be setting up the Windows Home Server, but more about that in Part 3.

Building a Windows Home Server – Craftsman Style

PART 1: A Plan Comes Together.

I told myself that there weren’t going to be any major computer builds/rebuilds this year. I was going to give my wallet a year off. But previous builds and upgrades had left a legacy of unused parts, and I began to consider “throwing a few together” to build a Windows Home Server, just to see what it could do. A server, I thought, doesn’t need a monitor, keyboard, mouse or fancy video card, so it shouldn’t be too expensive. What it would need is something to house it in. I kept the idea in the back of my mind, and then last month when I was thinking about building a new storage cabinet for my home office area, I had an idea to combine it with the server project. I would build the server into the cabinet. A beautiful symphony of woodworking and computing all in one project.

Cabinet Design

My preferred style of furniture is American craftsman style, and I already had a vaguely craftsman style music cabinet in the office area that I wanted to match. To fill the space available, I decided that the cabinet should be about 1.2m high, about 0.6m wide, and about 0.35m deep. I sketched it out with a single door, and five shelves, the bottom shelf being quite deep to accommodate box files. The next shelf up is where the server would be, built into a removable drawer so that it could be easily serviced. As I do not have ready access to a supply of quarter-sawn white oak, and I didn’t want to spend a fortune, I decided to build the cabinet out of plain old pine, stained to a nice deep craftsman brown. My wife and I had previously built a cabinet like this, and it looked fine. And so it was off to the lumber yard.

Selection of Server Parts.

Early on I thought about using a spare ASUS 915P based motherboard I had in storage. It turned there were two problems with this, firstly it was a full ATX board and my available drawer space was limited, and critically, when I tested it I found it was broken. This wasn’t entirely unexpected as I had used this board with an after-market air cooler which used a stick-on back plate. When I removed the board from service, I tried to remove the back plate and ended up damaging the board (I learned my lesson, and next time I came across one of these back plates I left the paper on the adhesive and secured it with the bolts alone).

I considered that my key requirements for the server were very quiet operation, as I didn’t want an annoying noise coming from the cupboard, and low power consumption, as I anticipated leaving it on all day. I also had a spare CPU, but it was a hot Prescott core P4 540. I decided that it would be best to sell that and buy a new low powered processor. Next I considered an important part of any server, the storage. I have a couple of spare 160GB Seagate SATA drives, but I also discounted these on account of their loud seek noise and limited size. I wanted to start with a nice fast, quiet, large drive for the primary partition. Just one drive to begin with, especially considering the data corruption bug in Windows Home Server (power pack 1 beta had not been released). So much for my plans to use left over parts. In the end, after much research I chose the following parts that I thought met the bill:

Motherboard: Gigabyte GA-G33M-GS2R
CPU: Intel Pentium Dual Core E2180, 2GHz
Hard Drive: Samsung HD753LJ, 750GB

The one part I could recycle was the RAM, as I had a spare 2GB Corsair DDR2 1066MHz kit, massive overkill, but otherwise sitting on the shelf unused.

The reasonably priced G33M-GS2R features an unusual mix, for a micro-ATX board, of integrated video (required for easy server setup) and quality components like all solid capacitors, 1Gbps LAN (also essential) and six SATA ports fed by an ICH9R southbridge. In fact one reviewer on the internet wondered exactly who Gigabyte were aiming the board at for this reason: well server builders of course! By the way, the fancy copper northbridge heatsink shown in the photo does not come with the board. After initially examining the board, I did what you shouldn’t, and held the board in one hand by its edge and northbridge heatsink to put it back in the bag. I felt the heatsink give, and knew that I’d broken the thermal material interface. Since I had to remove it and replace the TIM, I took the opportunity to fit a spare Swiftech heatsink (minus its little fan to minimize noise) I had left over from a previous upgrade.

With the parts sorted, it was time to get on with the cabinet build. More about that and making the server in Part 2.