Link to youtube video
showing the build and boot process. | Download the
STL files, including speaker model.
New youtube video showing
improvements to the build (1/20/23)
Designed over the course of DOScember
2022, this build went through a few design choice changes.
(click on images for larger
image.)
Originally, was designed around a
Raspberry Pi 2B.
  
Then, was redesigned after
discovering that the Dell WYSE 3040 thin client would fit inside the
design perfectly.
The finished product has multiple
files, The original top case with separate 5.25 and 3.5 bays, which
the 3.5 bay is designed to hold an SD card slot. The power button is
8mm diameter, so you can use the model for an authentic button or an
8mm panel mount switch like I wound up doing. The alternative top
case has the 5.25 and 3.5 bays built in so you don't have to print
them separately. It also contains a 5mm hole for an LED on the left,
and a recessed 1cm x 1cm square for a tiny case badge. There are two
versions of the bottom case as well. One for a full size Raspberry
Pi, and one for the WYSE 3040 motherboard. The WYSE design has the
standard ports as well as a spot to put a USB to PS/2 adapter.
 
In my current build. I removed the
front USB 2.0 port, and added header pins. Then added some dupont
connectors to the PS2 adapter, so I could disconnect if I need to
remove the board.
Here is what the build looks like
currently
This is using the new case design, with
the inset PB logo, a tiny 'intel inside' sticker (10mmX10mm), and
the addition of the LED hole for power light. Also using an 5" Eyoyo
S501H monitor (VGA, HDMI, RCA in)
I am running NTDEV's Tiny10 21h2 x64
(download) version on this build. The WYSE
only has 8GB of onboard storage and 2GB of RAM, but it runs great. I
disabled hibernation and page file, and compressed the disk to have
over 2GB free space. Plenty for DOS and Win3.11.
I have a registry edit to allow auto login, another registry edit
from embedded windows that skips the login screen completely, and
then a scheduled task that loads DOSbox-X on login, right into full
screen. Besides the OEM Dell logo in bios when it boots, it'd be
very hard to tell what this machine really is. You see the Dell logo
for a moment, then the PB logo, no loading swirl from windows, and
then bam, right into DOS. Now I have a custom DOS boot process,
check out the new video at the top of the page to see. Going to add
the EXE file here soon, as well as the QuickBasic 4.5 code.
Upgrades and tweaks that are coming soon:
- (done) 90 degree 3.5mm headphone
adapter + 6 inch 3.5mm male to female panel mount adapter, to
have an audio jack in the rear
- (done-ish, left it internal to
add usb flash drive for extra storage) 90 degree USB 2.0 panel mount
cable to move the remaining front USB to the back
- (done) Replacing the top case with the
new model
- (done) 5inch LCD monitor to fit the
theme
- (done! see pic above) Tiny speakers which I am
currently building. They will need paint and a 3watt amplifier
is on the way for that
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