Part 2 - Patterns and Templates
Although I had test fitted all the parts in my mind and taken a rough measurement of the Yosemite motherboard and Macintosh IIcx case, I needed accurate measurements and didn't want to be handling the parts unnecessarily during modification of the case. Therefore, I took careful measurements of all the expansion cards, CPU/HSF, memory modules, and auxilliary logic boards. These were then used to create wooden and plastic facsimiles that could be handled without fear of destroying some valuable hardware.

After carefully taking all the measurements I thought I would need (and rechecking them several times), I carefully disconnected all the ribbon and power cables and removed all the expansion cards, RAM, auxilliary logic boards, and the processor/HSF from the Yosemite motherboard and put them away until their later re-installation.

   
  Bare motherboard.  

Now I was ready to make the mock-ups. The logic board mounting points, PCI "keep-out" zone, and external connector area (USB, FireWire, ADB, audio I/O) were my first priority.

Since the motherboard mock-up would have all the other mock-ups attached to it, I made it first from a piece of scrap 5/64"-thick (≈2.0mm - about the same as the motherboard) polystyrene sheet I had handy.

After verifying the plastic sheet was accurately cut to the same size as the motherboard (it was), I placed the motherboard on top of the plastic sheet and carefully marked all the mounting points with a large-tip permanent marker, using the motherboard mounting holes as a guide. The diameter of the felt tip was nearly the same as the mounting holes, so everything lined up relatively well.

   
  Marking the mounting points.  

I then used a center punch to mark each mounting hole. Each hole was then drilled out using a 9/64" (≈3.6mm) drill bit and a mini-drill press.

While all the PCI cards were still installed in the Yosemite chassis, I took length, width, and height measurements of the space they occupied. From these, I created a wooden mock-up of the PCI "keep-out" zone using scrap 3/4" (≈19.1mm) clear pine stock. I then removed the logic board and all its installed components from the Yosemite chassis and installed the plastic motherboard mock-up I had made in its place.

   
  Test fit. The cross-hatchings marked holes that were already in the piece of scrap plastic. I didn't want to mistake these for mounting points later on in this project.  

Then, I put in some blank PCI slot covers into which I had drilled two holes each for mounting directly to the PCI "keep-out" zone. In this way, I was able to accurately position the PCI "keep-out" zone for attachment to the motherboard mock-up. Which I did.

   
  Mock-ups assembled.  


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