Building a wooden PC case was my first YouTube Video and my first woodworking project. I think this challenge was kind of reckless with the skills and tools I had. Though I really enjoyed this project and learned a lot.
Project Summary
I made a wooden PC case. The PC case is basically made by 5/8″ and 3/8″ square dowels (poplar) and regular popsicle sticks. Of course, I used other materials, too but these are the main materials.
- Tools I used
- Hack Saw (Not Recommended)
- Pull Hobby Saw (Recommended)
- Drill
- Circular Saw
- Chisels
- Router (Optional)
On this page, I will share the tips I found during the build. It’s probably good to know if you are a beginner of woodcraft and building a similar pc case.
For the steps of how I made it, please watch the video.
My Findings
Choose the Right Tools and Materials
Get a Pull Hobby Saw
When I started this project until finishing the popsicle Kumiko, I basically used a $10 hacksaw from The Home Depot. I made it somehow but because the hack saw’s blade is thick yet easily bent, it was really hard for me to fabricate each piece accurately.
Then, I happened to find the existence of a pull hobby saw and I got one for about $5( it was blade only so I got a handle for another $5). This saw made a major difference in accuracy and I regret that I did not research about it before starting the project.
How is it different? The saw blade and the kerf line is so thin but it has a supporting metal so it doesn’t bend easily. On top of it, the teeth is very tiny so you can make a real fine cut. Of course, it can’t cut the thick wood but it’s a must have item for this type of project and it’s cheap.
As of now, after I tried several cheap hobby saws, I recommend the Xacto (Xacto Razor Saw) one or Hobby Lobby one for the teeth quality. I just said it doesn’t bend easily but don’t expect they will last long. It might accidentally bend or the teeth may break as you use.
Quality of Popsicle Sticks Matters
I bought cheap popsicle sticks from Amazon and have never checked how ones from other places looked like until I went to Hobby Lobby. The cheap ones tend to have lots deformed ones and even if it’s straight, the consistency of the thickness is off. If you check the picture below, it’s obvious.
I don’t say all cheap ones from Amazon are bad but for safe, if you pay a couple more dollars at a craft shop, you’ll be able to get quality sticks and it will make a significant difference. I regret that I didn’t check local craft stores before the project.
Anyways, if you want more accuracy, you can consider using craft sticks that I used in the next project. Please check the next post of “Soundbar from Old PC Speakers Kumiko Style” for more detail.
Poplar Dowel is Good
I just happen to grab poplar square dowels instead of pine, the cheaper option but I’m glad that I got poplar ones. I don’t mean pine is bad but poplar is pretty straight and easy to fabricate.
Polycarbonate Sheets
Polycarbonate sheets look almost the same as acrylic sheets but It’s way easier to fabricate. It’s hard to be chipped or cracked even when you are drilling closed to the edges unlike acrylic sheets.
The bad thing about it is, it’s not as clear as acrylic sheets and it gets scratched a little easier than acrylic ones but it’s not that much different. So, if you want to use acrylic sheets like how I used, polycarbonate sheets can be a great option.
Aluminum Angle
I used 1/16″ thick 1/2″ x 1/2″ aluminum angle for the front 14 mm x 2 fans bracket. Originally, I used a flat aluminum bar but that was too weak for it. I strongly recommend using what they call angle ones, the L shape ones.
Plywood is a Better Choice
I used 1/4″ x 8″ poplar board for the back panel but this was a mistake. Ones like 1/4″ thick with around 8 inch wide solid wood I chose are relatively weak for the grain direction. Therefore, you need to have good amount of distance between cutouts for devices or it breaks so it’s not a good choice for the pieces like the PC case back panel.
On the other hand, plywood is solid and you don’t really have to mind about the grain direction of the cutouts. It can be common sense but I didn’t know and I should’ve used plywood for the back panel.
Building Tips
Marking Accurately
The other tip I can give you is, marking the line very accurately with a really sharpened pencil. I first used a dull pencil but I wasn’t able to lay a fine line beside the ruler. There was a gap like the picture below and also the line by itself was pretty thick that made me confused if to cut inside or outside of the line or it gives unwanted gaps later.
Please use a sharpened pencil.
Wait Wait Wait
When you glue pieces, be sure to use clamps and wait enough time for the glue to dry. I mean, if it’s half way dry and you move on to other parts, it may be slightly dislocated and it looses the accuracy.
If you want to increase the building speed, you definitely need more numbers of clamps.
Popsicle Stick Fabrication
I made popsicle sticks into Kumiko, butcher block and herringbone style and I was surprise how they are solid when bunches of them get together and it looks kind of cool. Additionally, they can be easily sand with a 120 grit sanding paper so please don’t underestimate popsicle sticks! I think it can make a good accent for your project.
Oil Sanding
For butcher block/herringbone style popsicle sticks, I sanded up to 400 grit before applying mineral oil. When applying the mineral oil , you can sand them with 600-800 grit sanding paper for the last coat. I found if you do it for the first coat, the wood doesn’t absorb the oil well. This makes the popsicle sticks shine!
PC Case Things
Device Location
As I didn’t have extra pc components to dry-fit, I printed out screw patterns of each device and place it over the wood to see if they fit okay as well as marking the locations where to screw in. Blueprint of each device that have standards like the motherboard, PSU, and GPU are easily available online so it’s good to use them.
Additionally, like I mentioned in the video, a blueprint sometime indicates the size of cutout length with less than 1mm unit. Let’s say rear I/O panel width is 158.75mm. If that is the case, I would say just cut it out with 158mm and if it runs too small then sand it to adjust the width later.
Misc
If you want to build a PC case, here are the stuff you might need to get aside from the materials to build the case (the links below are Amazon Affiliate).
- Case fanM5 screws. Get the length you need depending on the thickness of your case.
- MotherboardM3 10mm Stand off and M3 screws. The clearance between motherboard and the board you place motherboard on has to be 6mm(about 1/4″) or more but I recommend 10mm(3/8″). It is because GPU tab is longer than 6mm (less than 10mm) and it interferes the board you place your mother board on if you use 6mm.
- PSU/GPU tab#6 – 32 screws.
- Front I/O USB I used RGEEK 2.1 feet Dual Ports USB 3.0 from Amazon
- Power SwitchI used KNACRO 16mm Chassis Switch Metal Button Switch from Amazon
- Dust FilterI used MNTT PC Case Dust Filter Computer Mesh from Amazon
Just Try
If you feel like making one, just try it! Building a PC case require you to think a lot like how you can achieve accuracy, functions (air flow/maintenance), and of course the looks so it’s a great woodworking learning project. It may just end up costing more than buying a premade nice looking case though…