Introduction: USB3.0 External Case for 5.25" Blu-ray Drives
If you have an optical drive sitting in an older computer, you don't use the computer anymore but you still wanna use the Blu-ray or DVD drive you're gonna need an adapter or even better a case which will enable you to transform the drive into an external portable device. I don't have a Blu-ray recorded in my laptop and they're quite expensive. Every time I needed to do a backup I had to copy the files on my older desktop computer first and only after that start burning the disc.
It was becoming a pain. So I thought I need to get that drive out that older computer and use it as an external drive.
I started to look for a case for 5.25" optical drives and I couldn't believe the price they sell for.
First of all they're not very common anymore cause, 5.25" drives are almost gone.
Second of all you really have look carefully because not all of these enclosures or cases will be compatible with your optical drive.
So I decided to design and build my own external Blu-ray drive, I started modelling the whole thing first, then bought a few things like the 3mm MDF sheets and the aluminum profiles, 3D printed some parts.
I also bought the USB to SATA adapter which is the most expensive part for this project. You'll need a powered adapter cause this Blu-ray drive draws 1.5Amps @ 5Volts and 2Amps @ 12Volts. And there's no way you can supply that directly from the USB port.
Supplies
Used tools:
Saw, Cutter, Ruler, Calipers, Sanding paper
Materials:
- SATA to USB3.0 adapter. Here's a link for the one I used. Disclaimer: I'm not sponsored by the seller or Amazon.
- I used MDF coated on one side 3mm thick but you can use any type of material you're comfortable with. All that matters is the thickness (3mm) if you don't want to re-calculate all the dimensions
- L shaped aluminum profiles 2 types:
15mm x 15mm (x 1mm thickness)
and
40mm x 15mm (x 1.5mm thickness)
- Metal plate (1.5mm thickness)
- 4 x M3 / machine screws / Pan Head / 19mm Long. You may have to adjust their length
- Glue. I used two types: fast and slow acting
- and of course the optical drive, I am assuming you already have
The total cost for this project excluding the optical drive: 23 $
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Important !!
although I successfully tested this case with two different Blu-ray drives, I cannot guarantee the dimensions I used here will work for your drive. I only had 2 x 5.25" internal drives to test with.
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Step 1: Prepare the Materials
EDIT: You can watch the video of this build here.
1. Begin by cutting the 5 sides of the case out of a 3mm MDF or plywood sheet.
Dimensions:
The Top and Bottom sides: 165mm x 189mm
The Left and Right sides : 43mm x 186mm
The Backside: 43mm x 165mm
On the backside, mark and cut the slot for the SATA / USB converter.
2. Cut the aluminum profiles to size.
L shaped profile (15mm x 15mm x 1mm)
4 pieces x 198mm long
and
2 pieces x 168mm long
Make the 45 degrees angle cuts (see pictures). Using a round file, make an arc shape on one of the 2 pieces which are 168mm long (see pictures).
L shaped profile (40mm x 15mm x 1.5mm)
2 pieces x 162mm long
3. Mark and cut 2 metal plates (Flat bar 1.5mm thickness), 162mm long, width anywhere between 25mm and 50mm.
4. Use the STL files to 3D print all the other parts.
5. Sand all the parts to ensure the best possible surface finish. Obtaining clean smooth edges and almost invisible joints, depends on this step, so don't skip this.
Step 2: Starting the Assembly
Make the front cover out of the two 3D Printed parts (3D Print 1a & 1b).
Clean the edges, sand the surfaces which will be glued and then glue the parts together, gently applying pressure.
Start working on 2 set of frames, one for the top side and one for the bottom side. Tap 3 aluminum profiles together. You can use a strong fast acting glue or any other method. Try to keep the glue surplus on the out area at minimum. Otherwise you'll have to sand the residue before painting.
When you have both frames ready, start painting. I used high gloss metallic finish, spray paint, Black and Orange.
Paint the MDF sides too. Depending on the color and materials you'll use, you may need to sand and apply more than one coats of paint. Just be careful with the amount of paint. It's always better to apply 2 separate thin coats than a single thick coat of pain.
When the paint has dried you can start assembling the top and bottom sides. Carefully apply a strong glue on the inner side of the L shaped frame and then bring in the MDF piece and gently apply pressure correcting any issues. Remember at this point your aluminum frames may be a little bit out of alignment. This is the perfect time to center and align everything. The outer frame must fit the MDF part exactly. Watch for 90degrees angles and nice parallel lines.
You may apply a little bit more pressure when you're done. Let the glue dry.
Put the top side away for now. We're gonna work on the bottom board for now.
Glue the backside of the case on the frame. Let it dry first and then glue the guiding metal plates on the bottom of the case. Take the optical drive measure and a make a sketch of the mounting holes. Mark those holes on the 45mm L-shaped profiles. Proceed with drilling the 4 holes for the mounting screws. When you're done test for perfect alignment by using the screws. If you manage to put all the screws in getting through the L-shaped profiles and into the mounting holes of the optical drive, then it's all good.
You may now proceed to the next step.
Step 3: The Lateral Sides and the Top Cover
Glue the 45mm L shaped aluminum profiles on the bottom side. Use the optical drive, the front cover, the lateral sides and the L-shaped spacers to center and align everything. Watch for perfect mounting holes alignment. The holes on the lateral sides of the front cover should be aligned with the holes in the L-shaped aluminum profiles and the optical drive.
When the glue has dried remove the optical drive, the front cover and the spacers. Use a pencil to mark the centers for the mounting holes on the lateral sides. Remove them and drill the 4 holes.
Now you can glue the lateral sides in place. Apply a small amount of glue on the lower part of each lateral side. See the picture (green marking). Use all the other parts (optical drive, front cover, L-shaped spacers) to make sure everything is centered and well aligned.
When the glue has dried you can start working on the top cover.
Glue the MDF top board on the aluminum frame and let it dry.
Remove the front cover and the optical drive on more time and glue the supporting part which sits underneath the SATA adapter.
Step 4: Almost There
We're almost there.
Insert the SATA adapter into the optical drive's connector. Reinsert the optical drive and put the front cover on.
Put the top cover on and place the 3Dprinted parts on the lateral sides making sure the holes are aligned.
Initially, I was planning to glue these parts on the top cover's frame, to ensure that the top cover cannot be removed without removing the screws. But after doing all these steps I got a perfect / tight fit. So you should decide what's best for you.
Now you can use the 4 mounting screws to secure everything in place.
Step 5: Finishing Touches
The last step was to glue each segment of the "X DRV" letters on the top cover. I use very small a amount of glue !! working my way from top to bottom.
Congratulations. You've just built your own optical drive external case / USB3.0 compatible.
You should be proud of yourself. Go get a cold beer and show the world what you made !
Visit my Youtube channel for the video of this build and other projects, mostly hardware related.
Step 6: Changing the Drive Letter for the X-DRV
This is optional but cool. I selected the letter "X" for my new external Blu-ray.
Here's how you do this in Windows:
Right click on your "computer". Click on "manage".
A new window will appear. Click on the left pane "Computer Management (Local)" then click on "Storage / Disk Management".
Wait till the disk configuration management loads, then look for your optical drive in that list. When you find it, right click on it's name and then click on "Change drive letter and paths"
Click on "change", choose the letter you want (if it's available) and click "OK".
Depending on what Windows version you have you may need to reboot in order to apply the new settings.