Custom pfSense Case

  • 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:

  • Very nice!

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


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