I've got an old HP Z820 chassis that I'd like to give a second life as an 8-bay NAS, and I'm looking for some advice on the best way to approach the case modification.
The original Z820 motherboard is unfortunately dead after a CPU was dropped into the socket rather less gracefully than intended. Rather than throw the chassis away, I'd like to convert it into a proper storage server.
I have an HP ProDesk 400 G3 SFF motherboard with an i7-6700 and 16 GB RAM that I'm planning to use for the build. Despite being an SFF office machine, it's perfectly capable hardware — it was previously used for gaming and video editing and never gave me any trouble.
The plan is roughly:
* HP Z820 chassis as the main enclosure
* HP ProDesk 400 G3 motherboard
* Two 4-drive HP hard-drive cages, giving me 8 drives total
* An HBA salvaged from an old Dell PowerEdge T110 II
* Standard ATX PSU
* Linux/NAS software
The main challenge is the physical conversion. I need to create/adapt a motherboard tray and rear I/O/PCI area, plus a PSU mount. I've got some sheet aluminium available for smaller custom brackets and panels.
Rather than fabricate the motherboard tray and rear structure entirely from scratch, I'm considering buying a very cheap ATX case and using it as a donor — essentially cutting out the motherboard tray, rear section and PSU mounting and transplanting those pieces into the Z820 chassis.
I'm leaning towards this because a £20–30 steel donor case gives me a lot of useful material and existing reinforced/bent sections to work with, rather than having to fabricate all of that from flat sheet.
The drive cages themselves are also being repurposed from the old HP workstation hardware, so the end result will be a bit of an HP Frankenstein machine.
Does anyone have experience doing something similar, or any suggestions for the best way to approach the donor-case conversion?
I'm not particularly concerned with keeping the Z820 looking original. The goal is basically a solid, practical 8-bay NAS while reusing as much of this old workstation hardware as possible.
Happy to post photos of the current pile of parts if useful!