Fan connectors to improve duct installation and removal. Thelio Io fan headers plug into connectors near the duct. Fans on the duct plug into the opposite connector. Installing the duct connects the fans to the Thelio Io. Needs to be modular to grow from one fan to six. (per carl)

New BIOS updates are necessary to support the latest Ryzen CPUs. Also, it seems like a recent BIOS update has a security fix, but I couldn't find details on what was included in that security fix.

https://www.gigabyte.com/Motherboard/X570-I-AORUS-PRO-WIFI-rev-10/support#support-dl-bios

Thanks for all you do

Verify Thermal performance with V3 chassis vs V2.

If we can adjust the main line on the stencil for the main bend on this piece, we might see better results with the bends / alignment to the front and back panels.

Setup ports

This is not personally an issue for me. But I've seen online comments by people who say it's a dealbreaker for them, and you should be aware of that.

I recently moved to a Thelio (generously donated by System76!) from a custom-built system with a high-end sort-of-gamer case called an NZXT (Model 700, I think). I say "sort-of-gamer" because it used design ideas from gamer hotrod systems while obviously being intended for a broader market - lots of focus on maintainability and upgrade-friendliness in the design.

One axis along which that case was well ahead of the Thelio's is sound suppression. Besides the now-usual 200mm slow-rotation fans. It did two things future revs of the case could usefully copy:

(1) A thin layer of acoustic foam on the inner walls of the case to absorb sound and dampen case vibrations.

(2) Contract points between assemblies are often (not always, but often) but often acoustically damped by rubber grommets or feet.

If you do these things, it is possible for a Thelio-class system to be whisper-quiet. I miss that about my old system.

Test bead roller

Review for fabrication, assembly and quality, update based on feedback and iterate.

cut/press/bend: ThelioV3 Sheet Metal

• PCI Bracket (THEALU-TBD4v9.step)
• Side (THEALU-TBD2 v40)
• Back (Thelio Back Panel v32.step)
• Base (THEALU-007004 v10.step)
• GPU Bracket (gpu brace v26.step)
• Brace (support bracket v29.step)
• CPU Duct (cooler2 v6.step)

And assemble

Move R&D thelio top case brace into a productive task.

Hello,

Would it be possible to provide a STEP file with the entire assembly ? And a second file that would be an assembly manual ? This could help many beginners to make their own equipment.

Thanks (and good luck for this new phase of your project).

Title says it all.

The nice custom Unix epoch zero fan grille on mine is slightly bent inwards because the top of it was the only place my fingers could get purchase when I was trying to shift the thing. I am sad about this.

I don't much care functionally whether the grips or indented portions are fore and aft near the top of either end of the lower frame or on either side of the case top. The fore-and-aft placement would probably be better structural engineering, as it would avoid hanging the weight on the lower frame off of six relatively small thumbscrews.

Major v3 R2 port diagram

I just glanced over the BOM in Common. Looks like you're missing the components for the Thelio-R2.

Move system to 2 part interna

Thelio
R1.6/R2.0/B2.0
Major
B2/R2
Massive
B1.3

Thelio case has no labeling on audio I/O jacks. This is an epic fail. If I have to explain why, you should be ashamed of yourselves.

Design & build

Found these U-Line mylar bags
and these (Amazon) dessicant bags

Production cant store cut veneer because it expands as it absorbs moisture.

Look into issue

Round 2

See issue #6 for backstory. Without intake filters my Thelio is going to choke on the dust - the question is only when, not if.

When you design these in, do it so that (a) the intake filters slide out for cleaning, and (b) they can be removed and reinserted with the machine in its normal operating position.

My old case had this feature. It was wonderful.

Mini cnc router

Looking at laser welding panels - Parts shipped 4/23 - JG
If works - laser weld/bend fixtures from sm

Single piece top brace design in process 4/27

Sample built w/approval 5/4
working on trumpf marking levels for alignment profile.

powder complete unit 5/4

Design

equal spacing for rings, smaller portions

Board

Black port openings on a black case may appeal to skinny-jeans hipster designers by tickling their ooh-minimalism response, but functionally they suck. Have mercy on people trying to plug in cables in dim light and cramped spaces.

Silk-screen white outlines around the damn things! Either that or make your port panel(s) out of metal with a finish that is not black. Visual contrast is everybody's friend here.

This is meant as constructive feedback!

After one year of usage my Thelio case is loosing its shape.
The wooden foil starts to get blisters and the edges start to bend upwards.

You should seriously think about material thickness, quality check and have some talks with people who work with metal parts every day (the ones who get dirty hands). Then bring an updated version of the case and maybe some ideas for us to fix some issues.

As soon as I have more spare time, I will start upgrading my Thelio case to be much more quit since the noise level is still the biggest issue..... will post my progress here...

This is my single worst problem with the Thelio case. I had to remove the case top to clear a cable that had shifted into an unfortunate collision with a fan blade, and despite many tries and much cursing have not succeeded in getting it reassembled.

Take this seriously, please. I've been tinkering with PCs and their cases since the early 1980s and I have never before seen one that was this much of a revolving bitch to put together. Seems like it requires some combination of secret black magic and the dexterity of a neurosurgeon.

I've been running the machine caseless for days now and this is not good. My office is dusty and without a case and good filters conductive dust will eventually get somewhere that will crash it. (I used to see this happen occasionally with the Thelio's predecessor.)

This problem is serious enough that I am contemplating transplanting the Thelio's guts into my old case to banish it.

I don't have any clear idea how to fix this.

THEALU-010010 -- seems to work based on Levi's initial testing. Needs mfg refinements.

create drawings for each of the following Thelio subassemblies

Get quotes & permit issues for bulk nitrogen

see mira for reference

Related to #6. I had a buddy who troubleshoots industrial computers for a living assist me in getting the case top back on the Thelio, because I couldn't. He poked around it a bit and said "Here's part of your problem" and then temporarily removed the part so I could photograph it.

https://photos.google.com/photo/AF1QipO0v9uXa0A30XOwsFC5C_b6ZmDwUw3SuV9XHU9b

Note the bent pins. It's obvious what happened; during one or more of my futile, profanity-laden attempts to refit the case top, they were misaligned and got mashed. My friend straightened then with a needlenose.

His verdict "Somebody got too cute." He thinks that should have been done with a conventional cable and a plug, rather than making the mating of the connector halves rigidly dependent on the alignment of the case top when it's pushed down - that was just asking for the failure mode presented at the image link. I agree.

In my opinion as an experienced PC builder myself, altogether too much of this case design needs to be shot and buried under a gravestone labeled "Somebody got too cute". Some of the ideas are really good, like the custom vertical drive cage. Some are insubstantial but fun, like the encoding of the Unix epoch in the rear fan grille. But there's too much about it that smacks of designers doing things because they could, without pondering whether they should.

Please think harder about serviceability and minimizing avoidable mechanical failure modes next time.

Lack of front- or top-mounted USB ports is annoying.

You may not think this is a big deal, but I use a very common Logitech trackball called an m570, a wireless device with a USB radio dongle. It can matter a lot whether that device is on the front, top, or back of the machine, because the low-power radio transceiver has trouble if it's too far away from or not in LOS with the trackball.

You're competing with cases that have this. It's pretty much a checklist feature for the high-end ones these days; you shouldn't get left behind.

Design this

Link to other table

create drawings for each of the following Thelio parts.

• back panel: side holes should be PEMs

• back panel: corners should be PEM

• back panel: increase standoff clearance in middle of panel.

• back panel: move drive cage lower

• back panel: screws hit extrusion.

• base: add PEMs to back side

• make PCI bracket

• case brace: reduce o'all length by 2x rivnut flanges

• side PEM standoffs: check antenna standoff hole size

• side: check head clearance for feet

• GPU Brace: check bracket range

• GPU Brace: should be M4 clearance, dont need extensions

Added Spacers to quote, waiting to pull trigger 4/23/21

On my Thelio the graphics card is kind of hanging down.

To fix this, I made the first modification on the case:
Cutting 2x M3 threads and fit in a screw to hold the weight of the cards. See attached pictures.

cut/bend prototype 3 components, 3 of each part.

https://www.dropbox.com/sh/wix64lzis58i90y/AADXITzAoZLguh6FOXASUDcga?dl=0

B
R1.6 r2

Need more info