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DIY pfSense Rackmount Router Build Log - Part 1

2015-09-12
all right so welcome to a pretty unusual build vlog around here we are gonna be building ourselves a badass new router yes we've got a wicked new internet connection we need a wicked new custom pfSense box to go with it so come along for the ride cuz this one I promise you is going to be interesting the mastercase 5 from Coolermaster gives you the freedom to truly make your mid tower case your own with modular parts and accessories click on the link in the video description to learn more you missed their lungs yeah first thing I need to do is follow my own rules about no garbage in the new office - next let's have a look at the hardware we're going to be using so step one is CPU we've got a low-power Intel Xeon CPU this is an e3 1260 L this is an Intel S 1200 KP server board provided by Kingston we've got kind of a special stick of memory in here so this is a low profile ddr3 dent we've got a 1u server case so this is a rack mountable case that'll be going in our new cabinet from norcombe you could install up to I believe an ATX sized board in here if you really wanted to but we're just going to be installing an ITX board because we're going to be using this space over here for an expansion card yes it's an i3 4 TT 4 quad port network card and we're actually going to be installing that sideways we're also going to need this was provided by Anthony over at NCI XO huge thanks to the MC IX tech tips crew this is a PCI Express extension what else we got for hardware now yeah we're gonna be using an SSD yes I know pfsense can run off a USB stick I don't care the next this is a really cool piece of hardware it so this a 1u redundant power supply so each of these is an 80 plus gold 250 watt power supply and then you can actually slide these modules out last piece of hardware this is a Super Micro heatsink and that's another challenge in one you case you can't even use a stock Intel cooler you might be thinking to yourself gee Linus that doesn't have any fans on it how is it gonna cool the CPU great question I think this is definitely the most constrained case that I've ever worked in the part I was worried about was the clearance at the back now I already know about some challenges that I'm gonna have fitting our power supply in this case so the board goes in here you can see all of my ports stick through just fine but the case is actually shorter and if standard high household if I mark this really carefully I can basically just hack it off with a dremel tool aha I'm getting so much metal in my eye not too shabby I hope oh my way overdid it look at that so that is what its gonna look like okay so the next step is to get our CPU installed so the CPU we're using is 1260 L we could swap this out with relative ease if we needed a beefier router let's go ahead and install our back plate oh okay this chip on the back is interfering with our back place shoot and we're gonna need the angle grinder for this this is not a dremel task okay not bad at all just clean it off I might want to take that in a little bit tighter so there we've dug out a little bit more material still fairly strong I mean strong enough to hold a cooler on so uh yeah there we go we've got lots of clearance around the contacts for that chip there so orientation here is key because the air flow only goes one way so our CPU cooler needs to be you have got to be kidding me we are making contact with the pins and the fan header right there so the speakers okay but that fitness to the pins has to go this is intended to sit right flat against the back of the board but there's quite a few things on the back of this board we might just barely be able to screw into that back plate and then this corner yeah that goes in it's a fair bit of flex on the board but nothing deadly not a thing yeah I think we should just hack off the top of this speaker - it should be enough to get the job done I just don't want those pins to touch yeah take that speaker we've been at this for like an hour and we've installed an IO shield and install the CPU in a socket I haven't even managed to put a heatsink on hold thermal compound there let's put the backplate on again so if I could just get this on here then we're good okay no clearance issues this time not too shabby next step put motherboard in case so this heatsink basically sits millimeters from the top of the chassis meaning that you cannot install a fan on there most one you coolers are like side blowers you know we wanted to leave ourselves room for a beefier CPU in the future if we wanted it so that option was not going to work for us we're gonna have to be careful when we slide this on we gotta cover ok this is the next big challenge I had no idea that there even were standards for when you power supply's these two are not the same one the way that this goes in just has absolutely nothing to do with what the back of this power supply looks like that leaves me basically cutting the case to get this in here so I need to get this in here and I need to secure it somehow you know what let's just hot glue it in because I don't feel that comfortable drilling into the side of a power supply the last place you want metal shards okay go in go in push down cable management is gonna be key for achieving any kind of proper airflow in a system like this yep power LEDs great so this my friends is where we start to get into why it was important that we use this low profile ECC memory a full-height dim would pretty much block air flow to our fins now some boards have the dims this way this one does not so we have to deal with what we're given to work with here next up mounting the PCI Express card oh cool you can actually install it either way Wow I don't know if we're even gonna get a 4x extender in here our cable management is done so we have a nice clear path two of those so we have a nice clear path from our fans to everything here that needs to be cooled the heatsink on our NIC the heatsink on our CPU and all that's left to do let's close her up and find out how she runs now what I'm actually gonna do is put Windows on this machine first just so that I can use nice familiar testing tools in order to evaluate cooling because I am a little bit worried about this CPU so we were defeated we were defeated by a dead mother born but eBay to the rescue I can't say enough good things about eBay I ordered this motherboard a 250 watt power supply and four gigs of RAM at least I cut the motherboard fortunately I didn't need that other crap so let's go ahead and rebuild the machine this time with a Oh working motherboard oh crap I can't even do it right the second time around let's try putting the actual cooler backplate on here I don't know how I missed this before but on the old board which fortunately we can now use as a tester for the additional cutting that it looks like we're gonna be doing there are a couple of components here that are clearly interfering with the backplate still so we actually need to do more backplate cutting so in theory this one actually fits on the board ok great it shouldn't be this much effort I build a router this is why most people probably buy order Nina have them at the store they have a whole aisle called routers ah alright and this speaker you know just rip this off this time that seems ill-advised on my working board doesn't it you could use the sacrificial board to find out if you can rip the speaker off okay you can't now we know we can use a dremel if I can find it oh yeah there it is sure there we go in theory we are ready let's sleep it's on nothing ever takes as long as it's supposed to okay that's in let's put our cable management nonsense back into place that's nice least I don't have to plan out the cable management anymore since I've already done it once there we go okay so that's good so in theory this time this stupid thing powers on come on baby please work what okay I'm at a total loss right now I'm not sure what just happened I have nothing to say at this point I I think something about our config just killed another board but I don't understand why that would happen because the only thing in here that I haven't run in this board before is a PCI Express riser and RAM which shouldn't make a board scream and then die it's unheard of but I think we just killed another board exact same behavior as last time we're getting beeps and then we stopped getting beeps our working hypothesis right now is that this is some kind of connector that I've never seen before and was actually providing power to the motherboard instead of acting as like an RPM sense or something so we're testing with the multimeter now we just bricked two boards time to order another one I guess sue tuned for part two so I learned a lot in this video you know what else I learned Squarespace their websites look better than me writing on a chalkboard yes my friends they do with Squarespace calm you can build yourself a beautiful functional website that serves whatever purpose it is that you're into you want to make a website about Luke having the best butt in the biz or how it doesn't you can do that you can make a blog you can make a personal portfolio you can make a hey you can make a store you can have a store where you sell you know license plate covers that say Luke has best but in biz or you know something people might actually want to buy say for example so head over to squarespace.com slash I think it's Linus I should know this kind of thing by now so head over to squarespace.com and if you guys use offer code line you can save 10% but you don't have to buy it upfront you guys can try it out for a couple weeks for free they do a free trial you can play around with their tools they've got 24/7 tech support so if you're having trouble building your site you can reach out to someone via email or a live chat and get them to help you out great stuff they've got all kinds of stuff that like I used to talk about but isn't in my talking points anymore but I still think is cool like their little logo builder app and they've got this really cool thing coming up that oh I guess I wasn't supposed to talk about that sorry sorry well whatever they're always developing their tools and making them better all the time so squarespace.com make a beautiful website all of your own alright so thanks for watching guys if you disliked this video as much as I disliked making it then press like also if you liked it press like and if you liked it then maybe you'll consider supporting us either by buying a cool t-shirt like this one directly through our community forum or by changing your Amazon bookmarks once our affiliate code you can find the instructions for how to do that up in the I in the top right corner I think that pretty much wraps it up though thanks again for watching and if you're wondering what to do next now that you've done all that stuff because you liked the video maybe check out channel super-fun where we've got a new video that just came out where we eat bugs it's gross but cool
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