Project information

Title : Adding a front panel connector to a tiny PC

Date : 06/07/2026

Description : I added a front panel connector to a tiny PC case which did not have one

Problem : The case I bought was just the right size and fit some brilliant hardware, it just didn't have a front panel which was super annoying.

Overview

I upgraded from my Acer Veriton L4620G, a brilliant little machine but it was getting slightly older for my use, I wanted to ensure that I would be able to keep upgrading in the future so chose a case of a similar size but which fit mini-itx sized motherboards.

Using a caliper I measured the front ports of the front panel I ordered, I then used these measurements to create an SVG cut file with signmaster and my cutter. After making a mask I cheacked it carefully against the actual ports and adjusted it as needed (repeated the process) until I got it perfect.

I drilled holes in the chassis to remove as much material as possible, I did this with a wooden block underneath so the metal panel would not warp. I then proceeded to file the excess and testing that the ports fit nice and snug. I had a couple very minor slips when filing out the holes for the ports but it actually looks spankin' considering the amount of work and room for failure.

I modified the connector so it would fit as sug as possible, I wanted it to be close to the left side and on the bottom as this looked natural and also aluminum SSD cases can scrape across the front panel paint if up too high.

I cut the original board because apart from the audio jack it was mostly just a PCB to align the components up, I used two layers of MDF wood to get a depth perfect for having the ports just poking out from the case but still flush.

I used liquid nails construction adhesive to adhere the block of wood internally and then I clamped it for 48 hours before using it. If I hadn't had experience with how incredibly strong liquid nails is I probably wouldn't have trusted doing this method. This method allows for a flush finish.

All done and looking awesome, 1x USB-C, 2x USB-A 3.0 and lastly a front audio connector that I may never use :).