Project: The "Windows XP Box" (2003)

Author: Andy France
Date: December 1, 2003
Source: mini-itx.com

📦 Introduction

The goal was simple: I needed a compact machine capable of running Windows XP. Given the size constraints, a Mini-ITX motherboard was the only logical choice. To make the project thematic, I decided to house the entire computer inside an actual Windows XP retail box.

The physical constraints were incredibly tight, with external dimensions measuring: $\text{Length: } 243\text{mm} \times \text{Width: } 200\text{mm} \times \text{Height: } 48\text{mm}$

Project Requirements

To ensure the build was successful, I established a set of strict criteria:

Requirement	Priority	Note
Performance	High	Use the most powerful motherboard possible for this form factor.
Optical Drive	High	Must include an internal CD drive (this proved to be the hardest part).
Aesthetics	Medium	The cardboard box must not bulge or be modified in size.
Safety	Critical	The system must not $\text{combust}$ under heavy load.
Legacy	Low	~~Internal Floppy Drive~~ $\rightarrow$ Not required.

🛠️ Construction Process

When the components first arrived, the project seemed nearly impossible. The volume of hardware compared to the available space was daunting. Interestingly, the Windows XP box was actually $12\text{mm}$ narrower and $3\text{mm}$ thinner than an Adobe Acrobat box I had previously used for measurements.

The "3D Jigsaw" Challenge

The build was essentially a spatial puzzle. I started with very slim margins:

Length: Only $6\text{mm}$ of spare room.
Thickness: Only $3\text{mm}$ of spare room.

Material Choice: I opted for Wonderboard plastic. While aluminum would have been sleeker, the cramped quarters made the risk of a short circuit too high. Wonderboard is sturdy yet easy to manipulate with a standard Stanley knife.

Spatial Layout & Tolerances

Once I added a $3\text{mm}$ Wonderboard base plate, my tolerances dropped to zero. The components had to be packed with surgical precision:

Detailed Fitment:

CD Drive: The deeper section of the drive pressed against the motherboard's heatsink, while the thinner section overlapped it.
Motherboard: The board's edge touched the inner case wall, the sound connector touched the support structure, and the bottom of the PCB rested against the cardboard.
Hard Drive: This was tucked underneath the motherboard, utilizing the space above the unused PCI slot.
Power Supply (PSU): Positioned above the hard drive, with the bulky cabling facing the CD drive.

🏁 Finishing Touches

After extensive cutting and using nearly half a tube of adhesive, the internal chassis was complete. I utilized pillars to secure the PSU and three corners of the motherboard, while dedicated brackets held the HDD and CD drive in place.

Thermal Management

Cooling was a primary concern given the density of the build. I implemented the following:

Fan Mounts: Installed in opposite corners to maximize airflow.
CPU Ducting: Cut a dedicated aperture in the side of the case and glued plates to create a duct, ensuring the CPU fan drew in only fresh, external air.
Custom Guards: Since drilling dozens of tiny holes is tedious, I used an angle grinder to cut fan guards from a metal speaker grill.

🔗 Quick Navigation & Resources

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