The "Windows XP Box" (2003)

A compact DIY build that squeezes a Mini-ITX Windows XP machine into a retail Windows XP box (external size 243 x 200 x 48 mm). The goals were strict: use a Nehemiah EPIA M10000 board without cutting any parts, include an internal CD drive, keep the case flush (no bulging), and ensure safe cooling. The builder treated the challenge like a 3D jigsaw, measuring tight tolerances (6 mm spare on the long internal dimension, only 3 mm on thickness) and planning component placement precisely so everything would fit without enlarging the box.

Construction used a custom inner support case made from 3 mm Wonderboard plastic that slides into the cardboard shell. The CD drive sits hard against one side and brushes the motherboard heatsink; the hard drive slides under the motherboard above an unused PCI slot; the PSU fits above the drive with connectors pointing down. Pillars and brackets support the board, drive and PSU; fan mounts in opposite corners provide intake and exhaust, and a cutout with glued duct plates forces the CPU fan to draw cool outside air. Tools and materials included a Stanley knife, glue, and an angle grinder to make fan guards from speaker grill; cooling and safety were emphasized throughout.