First post, by ddoyle525
For quite some time I have been wanting to build a 486 PC similar to the original 486DX-33 PC I bought back in 1993. While searching for parts online I noticed that 486 AT-style cases were difficult to find and often expensive and in rough shape. Fortunately, I found a very nice 486 desktop case in the Netherlands so I decided to take a chance and purchase the case. Unfortunately, the case arrived badly damaged. Several of the plastic mounting posts for the front bezel had broken off. Furthermore there was no power switch, no power switch mounts, and the 3.5in hard drive bay was missing. What started as a simple PC build quickly became a significant repair project.
Before I go further I would like to thank Almighty God for His love and answering my prayers and giving me the talent and perseverance to take on these projects to their completion. Also for the Vogons community, and other retro-computing enthusiasts like Phil's Computer Lab, DosDays, LGR and many others for all of the helpful articles, YouTube videos, etc. that made this happen. I am not a crafty person by any stretch and this was my first attempt at using a Dremel tool.
The first order of business was to repair the damaged bezel. I used drywall anchors to replace the broken mounts as shown below. I did this by trimming the anchors to the correct length and then applying JB Weld directly to the bezel where the anchors would go. While the epoxy was still drying I then bolted on the anchors to the metal case and then mounted the bezel to the case so that the anchors landed in the dab of JB Weld I applied earlier. This ensured that the anchors hardened in exactly the correct position.
The second step was to fashion a mount for the power switch. I was able to source a metal plate from another case and using a Dremel I filed away the excess metal around the plastic mounting posts and bolt it into place. I then glued on a plastic extender to fill the gap between the power switch and the power button on the case to give it a good feel.
The third step was to find a replacement 3.5in drive bay. By God’s providence I located a drive bay from an old Dell Dimension that I found in the warehouse of a computer recycling shop. I just had to cut away the excess length with a Dremel and it fit perfectly!
Once the repairs were completed I began the process of ordering parts from eBay to get things working.
"Jesus said to him, “I am the way, the truth, and the life. No one comes to the Father except through Me." - John 14:6
