1. Join Date
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    #101

    MacTester57's HemiMac G4


    MacTester, do your backlights stay on or go out when only display sleep (not full system sleep) is activated?
    I believe, that it stays on. Not really an issue in my eyes. The Hemi is not able to run at the moment, because the finalizing of the bottom plate wiring is in progress...

    Removing the border on the USB sockets to allow to lower them into the original holes:


    Fixing the USB sockets with hot glue and a zip tie. No difference to the original condition will be visible from the outside:


    The routed cables on the bottom plate. Everything must be routed very clean and well thought to allow the assembly of the bottom plate. The following modules will be mounted to the bottom of the DVD drive: BT, chime sound module, sleep- & PSU controller (not yet mounted on this picture). The USB hub is mounted to a pvc frame, which is fixed with two of the original logicboard screws. It uses the last available gap between the optical drive and the original chime speaker:


    The bottom plate will fit! Hope, that the signal strength of the BT module will be good enough through the plastic darning in the outer bottom shell:


    Now I will have to wait for the 90° angle 2.54mm pins for the sleep controller...

    MacTester
    Last edited by MacTester57; 09-04-2013 at 03:58 PM. Reason: Typo
    HemiMac G4: Intel NUC DC53427HYE / Internal DVD drive / Internal PSU / Touch sensor LCD dimming / Mavericks 10.9.1
    Mac Audio: Intel DQ77KB / Core i3-3225 / HD4000 / Mavericks 10.9.1
    G4 Cube: Intel DQ77KB / Core i7-3770S / HD4000 / ACD 27" / Mavericks 10.9.1 (Main System)
    G5: GA-Z68MX-UD2H (v1.3, UEFI U1d) / Core i5 2500K / HD 3000 / Mavericks 10.9.0 (Test System)

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    iCubeFan is offline
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    #102

    MacTester57's HemiMac G4


    Impressive job!! I'm enjoying ( and learning ) a lot reading both this thread and Ersterhernd's

    How good is the sound from the USB Audio card ? Is it worthy? They're so cheap that I may order some for future projects.

    Cheers
    iCube & iMac Fan

  3. Join Date
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    #103

    MacTester57's HemiMac G4


    Impressive job!! I'm enjoying ( and learning ) a lot reading both this thread and Ersterhernd's
    Thanks!

    How good is the sound from the USB Audio card ? Is it worthy? They're so cheap that I may order some for future projects.
    It's remarkable good. Better than the Amp with integrated USB receiver, which I've used in my cube speakers!

    The project is almost finished now. Only minor things are left to do. And then? ...

    The DVD drive with all the required electronics on its bottom side:


    The rewired Network port: GLAN works like a charm!


    The finalized wiring in the dome, before mounting the DVD drive:


    Everything is finished and ready for mounting the bottom:


    The finalized bottom plate wiring:


    The finalized connector area. The only visible difference to the original condition is the USB 3.0 connector in place of the former double FireWire port:


    The finalized Audio AMP with its 50KOhm stereo potentiometer. It's used to allow the adjustment of the maximum volume, so that the KB volume adjustment can work in a “hearable“ range:


    The completely wired electronics on the bottom of the DVD drive. To allow the easy remove of the drive, all external connections are made with removable connectors:


    The mounted inner bottom shell. All significant components are accessible through the opening:


    A front view with the opened DVD drive:


    And finally a back view:


    A small feature list:

    -i5 NUC
    -3 USB 2.0 and one USB 3.0 ports
    -reused original proprietary Apple speaker connector, fired from an internal AMP. The Apple speakers are in original condition.
    -Working LCD CCFL backlight dimming, using a Picaxe microcontroller and two touch sensors, which are embedded into the faraday cage. Works flawless!
    -Working internal microphone
    -Custom made sleep controller, using a 2nd Picaxe microcontroller. This allows to reproduce the Apple sleep LED exactly as it was in original condition! The "Apple Chime" startup sound is triggered from the same controller.
    -Reused original IDE DVD drive. An USB to IDE adapter was used. Watching DVD's with VLC works flawless!
    -Fully working sleep and rewake.
    -WiFi. The original antennas were removed and new antennas mounted instead.
    -The i5's Turbo States are not usable, because it's not possible to patch the BIOS of this NUC at the moment.
    -The following connectors on the back are only for "cosmetic purposes" and do not work: Modem (who needs this) line in, line out, Mini VGA.

    Conclusion:

    This was a fun project. Thanks again to dremeljunkie for figuring out the LCD pinout, to Ersterhernd for the inspiration and his ingenious touch sensor self calibration routine.

    Sometimes, I was a bit anxious, if everything would fit into the base... The goal to reuse the optical drive made the whole project very difficult and challenging. The brightness control and the sleep LED were not easy, too. This is by far the most difficult Hackintosh, which I've ever done!

    As you can see, it fit!

    MacTester
    HemiMac G4: Intel NUC DC53427HYE / Internal DVD drive / Internal PSU / Touch sensor LCD dimming / Mavericks 10.9.1
    Mac Audio: Intel DQ77KB / Core i3-3225 / HD4000 / Mavericks 10.9.1
    G4 Cube: Intel DQ77KB / Core i7-3770S / HD4000 / ACD 27" / Mavericks 10.9.1 (Main System)
    G5: GA-Z68MX-UD2H (v1.3, UEFI U1d) / Core i5 2500K / HD 3000 / Mavericks 10.9.0 (Test System)

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    #104

    MacTester57's HemiMac G4


    Bravo MacTester!

    Excellence once again!


    Ersterhernd

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    #105

    MacTester57's HemiMac G4


    WOW! I am very impressed with your work and attention to detail. My head swims when I try to follow what goes where and the fit. You are certainly a master craftsman in my book.

    neil
    Z77X-UP5 TH - i7-3770K - 32GB (4x8) - HD 6870 - BitFenix Black Prodigy hack
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    #106

    MacTester57's HemiMac G4


    VERY COOL. You have done an amazing job of that bottom panel, everyone thing so well organised. Congratulations. Kiwi

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    #107

    MacTester57's HemiMac G4


    Amazing Mactester!

    A perfect job! everything fits so nicley in there and its all so organized!

    Well done!

    Rick,

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    #108

    MacTester57's HemiMac G4


    Thanks for all the kind words, guys!

    Today, I've done some detail-works:
    1. Improve the airflow. To allow this, I've drilled some holes into the sheetmetal cage of the NUC and removed the lid in the air outlet.

    The four additional intake holes on the front side:



    The removed lid. I've also drilled two holes, where two holes in the heatsink are. This allows, that a part of the warm air flows directly to the case fan.


    The core temps after one hour of listening to music are about 50°C, which is about 3 degrees lower than before. It's still more than in ersterhernds iMac, but I think acceptable, because of the additional DVD drive, which produces heat too.

    2. Make the sleep LED work reliable. This was - ersterhernd would say a head scratcher -

    It did not always work. So I began to search the problem:
    -Are the signals slightly different in the finished build with its DVD drive??
    -Is the transistor defective?
    -Is the transistor current too high? -> not possible with a 56Ohm resistor!
    -Does the Picaxe work correctly? Works in the proto board!
    -Is the socket defective?

    I did not find any problem, but there was no signal on the output c.2...... I then wrote a test program, which activates the output all the time. In the proto board, I had a signal on pin c.2, but not in the definitive board!

    What the f..k??

    I then removed the PCB from the DVD drive and inspected its back side. Do you know, what the problem was? The base resistor of the BC548 for the LED pierced the double sided tape and sometimes caused a short on the DVD drive shell. Stupid, MacTester!

    Luckily no part was damaged and the LED does work as it should now!

    One problem persists: Sleep works only one times, if the DVD drive is connected and the DVD drive does not work anymore after sleep...

    MacTester
    HemiMac G4: Intel NUC DC53427HYE / Internal DVD drive / Internal PSU / Touch sensor LCD dimming / Mavericks 10.9.1
    Mac Audio: Intel DQ77KB / Core i3-3225 / HD4000 / Mavericks 10.9.1
    G4 Cube: Intel DQ77KB / Core i7-3770S / HD4000 / ACD 27" / Mavericks 10.9.1 (Main System)
    G5: GA-Z68MX-UD2H (v1.3, UEFI U1d) / Core i5 2500K / HD 3000 / Mavericks 10.9.0 (Test System)

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    #109

    MacTester57's HemiMac G4


    Hi MacTester, I was playing around with the Touch Sensor Brightness code tonight, and refined it to a point of VERY smooth adjustment.

    Here's 3 simple changes you can do to your code to smooth it out...

    1. Comment out ALL 'debug' statements. I discovered these slow the code WAAAYYYY down, and are only necessary in the initial programming stage.

    2. Change the brightness increment 'BRIGHTNESS_STEP' to 5 instead of 15.

    3. Add a 'PAUSE 20' statement as the first line of code under the 'loopstart' label


    Program the picaxe chip with these three changes and see how smooth and seamless the brightness adjusts up and down. I think you'll be impressed. If its too fast, just increase the pause slightly under the loopstart label. I'm really happy with it now. Going to re-program the other iMac tomorrow.


    Ersterhernd

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    #110

    MacTester57's HemiMac G4


    Quote Originally Posted by MacTester57 View Post
    How good is the sound from the USB Audio card ? Is it worthy? They're so cheap that I may order some for future projects.


    It's remarkable good. Better than the Amp with integrated USB receiver, which I've used in my cube speakers!

    MacTester
    Hi MacTester57,

    Yesterday I received the USB Audio card.I gave it a try in my NuCube ( iFire +Apple Pro Speakers setup ) and sound was fine at a low volume but when I tried it at higher volumes sound got distorted.
    I then tried the same audio setup with a Mac Mini ( with SL) and a MacBook Air ( with ML) and it worked flawlessly.
    Any ideas? Could it be kext related?

    Thanks
    iCubeFan

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