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    Custom pfSense Case

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    • N
      netmagi
      last edited by

      I posted a few weeks ago in the routing multi-wan group, and since then I've been planning on building a pfsense box to replace an aging cisco and sonicwall.

      I knew from the start I wanted to do something custom to fit in my mini rack, I just wasn't sure what.

      The co. I work for had a couple old ugly 2U rack mount cases, and I figured this might be a good starting point.  I picked one up for $10.

      I figured I could chop it up and build something with just "enough" for a pfsense box.  The donor case is almost all aluminum, which makes it very easy to work with.

      I started by chopping approx. 12 inches off the front of the case and making a new face plate with aluminum leftover from the chopped lid. Next I relocated a single 3.5 bay over the edge of the mobo and attached to the side of the chassis.

      For the front fan, I used a hole-saw to cut the opening, and a grill I had lying around.  The button and lights are from the original case front and are drilled/filed through the front of the face.  Tapped new holes for the rack ears, etc.

      The final result is about 15" deep.

      Hardware is:

      Intel 865 Motherboard w/Single Intel 10/100 NIC
      Celeron 2.0Ghz
      1GIG RAM
      160GB Enterprise SATA HD
      350W PS
      Intel Dual 10/100 in PCI Riser

      I may still modify it a bit more, but let me know what you think.

      Pics here:

      http://gallery.netmagi.com/v/projects/pfsense/

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      • chpalmerC
        chpalmer
        last edited by

        Very nice!

        Ive wanted to do something similar due to space constraints I have here.

        :)

        Triggering snowflakes one by one..
        Intel(R) Core(TM) i5-4590T CPU @ 2.00GHz on an M400 WG box.

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