Two Quick Fixes
Disclaimer: I am presenting the following two fixes for illustrative purposes only. They are my solution to the problems I perceived and are not condoned or recommended by Zalman. Both fixes require partially disassembling the case and removing the rear panel, which Zalman does not recommend. If you decide to attempt these modifications yourself, please accept responsibility for your actions and don’t blame me if you screw something up.
Fixing the lower PCI slot interference caused by the aluminum frame rail is relatively easy to fix. Here’s what I did:
- Remove the side panel door from the hinge pin brackets
- Install a PCI slot cover bracket in the lower position and mark the point of interference
- Remove the back panel
- Using a hack saw and file, cut a ¼’ by ¼’ notch in the frame rail
- Dress the opening with a black felt-tip pen
- Reassemble
Making the Side Panel Door Removable
My solution to making the existing door easy to remove requires modifying the two hinge pins. While very simple, it requires access to machine tools (mill and lathe) or a good friend who is a machinist… 🙂
- Remove the side panel door from the hinge pin brackets
- Remove the back panel to release the hinge pin brackets
- Be careful not to loose the small plastic washer under/around the lower hinge pin
- Reinstall the back panel without the hinge pin brackets
Hinge pins before modification
- Mill off the top pin section of the hinge bracket (new overall length will be 1.422′)
- Drill and tap milled end of hinge pin bracket with 10-24 tap
- Dress milled ends with black felt-tip pen
- Re-install the modified hinge pin brackets onto the door with the threaded ends facing out
- Machine a new hinge pin out of brass (.354′ dia x .216′ high)
- Drill and tap the new pin with 10-24 tap thru the center
- Screw a 10-24 Button Head SHCS x 3/8′ long into the brass pin (use Loctite 242)
- Lay case on its side and set door into position
- Make sure plastic thrust washer is in place on bottom plate (lubricate with silicone grease)
- Install the new lower and upper hinge pins (brass bushing with screw)
- You may need to adjust the position of the hinge pin brackets on the door to insure the door sits perfectly square in the case opening
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Lower Door Hinge Pin Installed Upper Door Hinge Pin Installed
With this modification the door functions normally when the case is standing up and still gives easy access into the left side. However, when I want to work inside the case, all I have to do is lay it down, take out two screws, and lift the door off!
