First job, Rip the laptop apart

This part was Fun !  See images below..  No, seriously, This took a while.  I disassembled the case, and removed the LCD from the motherboard.  I kept the motherboard without keyboard or trackpad and the LCD along with the metal screen on the back of the LCD.

Rebuild the laptop

I used a 16x10 frame from Homebase.  This frame has plastic sides which I thought would be great, but it turned out they flex too much and were hard to fix things to, next time, I'll try for an all wooden frame I bought some hardboard and cut a piece to fit inside the frame, I then marked where the screen would go and cut a hole.  I then carved out where the mounting lugs of the frame met the hardboard so the screen sat practically flush with the front of the hardboard.  It was then epoxied in (araldite).

After this was done I masked off the screen and connector and sprayed the whole thing matt black. I then used some offcuts of hardboard to fit a panel behind the screen with a small gap. I then mounted the motherboard to this (more epoxy).  I then attached the frame from a smaller picture frame over the mainboard, aften cutting some slots for the power, pcmcia, video, PS/ and USB connectors.

For the mount (or matt ?) I tried to cut one myself, but it took two hours, looked awful (the second one had blood on...).  I then went into Alnwick and tried the Alnwick Picture Shop, where the nice lady cut me a mount the perfect size in about ten minutes (after working out what I was trying to do), it only cost a pound as well !

I could then assemble the frame, glass, matt and hardboard containing screen and motherboard.  I glued the hardboard into the frame with a bead of bathroom silicone sealant (in case I ever have to get it out again). I epoxied two wire hooks onto the back of the frame at roughly 45 degrees, so I can add some picture wire and hang this on two hooks, its not actually that heavy.

I rewired the laptop power supply cable onto a piece of White Cat 5 (I know, 24AWG Cat 5 can't take the current, well I used 4 conductors for +ve and four conductors for Gnd, so it should be fine !) I also fitted a black push button into the smaller frame and soldered the wires directly to the laptop motherboard for a power switch.

Test and debug

When I turned it on. Eureka ! It worked first time.  Although it does have a slightly annoying habit of not starting / dying every so often if its been moved.  Its because the processor board comes loose, because its got three screws in it, none of which are in the corner where the connector is !  Its a known design flaw with the Cpi, and mine doesnt have the small metal clamp they used to fix it ! Well see how the family like it at Christmas.