In this update I’ll be working on a new rear frame for the chassis, and put a sheet metal skin on it to replace what I cut off.
I started out building an aluminum frame support structure for the back. I just used aluminum angle and rivets to assemble it (for ease of cutting).

The first piece was making 90 degree angle adapters for the end, set in so they would be able to fit inside the lid of the case once completed.

This will be the new back brace. The notch is for a part of the cover that slides in, where a screw is used to hold it against the back.

I added 3 supports that run forward that are used to mount it to the rest of the chassis and stop it from flexing.

I cut a piece of 1/16″ thick steel for the back plate and riveted it in place.

I replaced the old rear I/O panel of the motherboard tray I salvaged with one I bought from Danger Den. It should work better, and is a little easier to attach to the back panel.

I cut out the hole I needed for the rear I/O and PCI slots to be exposed through the back panel.

After the motherboard stuff, I cut out a place for the power supply to mount. This was a little tricky, as I had to cut out part of that brace structure I had made earlier. This seemed like the easiest way to keep as much of the aluminum angle in place, though.

I put in a mock power supply and the motherboard tray to get an idea for how things are shaping up. I’m pleased.

Leaving it off here, I’ve now got the provisions for installing a motherboard, PCI devices, and a power supply. I will start working on adding some fan mounting to this thing in the next one.
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