Sun Microsystems Ultra20/27 retromod prints

These prints should be compatible with both the Sun Microsystem Ultra 20 and Ultra 27 cases.

The project is mainly focused on retrofitting modern hardware into the Ultra series case with readily available parts. 

In this project:

• Front I/O PCB replacement

• Generic power button/switch extender

• (opt) Ultra 27 power button

More printable parts will be added as the project develops. 

Parts you will need:

• USB3 + Audio jack: https://www.amazon.com/dp/B0991QMCRV

  • Search: "USB3.0+USB3.0+HD Audio Cable"

  • There are a couple of different listing with what looks to be the same design. Be careful not to choose a USB2 version, as the project can not accept that plug. It must be 2x USB3.

• USB C: https://www.amazon.com/dp/B09YRMQT1F

  • Search: "GRAUGEAR 20Gbps Type E Key A Front Panel USB C Header Extension Cable"

  • Comes with a rear I/O plate that will be discarded. 

• Power button + LED:  https://www.amazon.com/dp/B074XDTVN1

  • Search Amazon for "2-Pin PC Power Switch Cable 27-inch Desktop On Off Reset Push Button" 

  • These are relatively generic/standardized size switches/LEDs, so the exact match might not be critical.

Project notes:

• Requires some de-soldering and destructive cutting (utility knife)

• USB C needs to be cut to fit.

  • The plug has locates/protrusions on the bottom that are a good starting point for cutting the plug. This trimming is required because the USBC plug can not be accessed with most cables if its recessed into the chassis as far as it is without trimming.

  • Be really careful not to cut your hands. You can always buy another cable for less than a hospital visit costs.

  • See images for clarification. 

• Even if you don't use the HD Audio ports, make sure you get the correct audio+usb3

  • This is because the USB3 ports are modeled off of the cables attached to the audio board.

  • The board include "locate" holes that help brace the usb3 ports when installed.

  • You can (in theory) add solder to said locating tabs after installing the cables into the PCB print. I did not do this, so your mileage may very. 

• The Front I/O stl will print with a "blocking plate" that covers the audio ports.

  • (opt) That material can be cut away with a knife if the audio jack is desired.

  • The audio jacks are spaced slightly further away from each other (15mm) compared to the stock holes (13.5mm). I found that this will still work if you trim ~1mm off the outer sides of each headphone jack plastic. 

  • I could not find a better off the shelf solution, so a slightly offset audio jack is the compromise. 

• The (opt) Ultra 27 power button is best printed horizontally, as printing it vertically causes the tabs to break on insertion. 

  • This was modeled from the original button design with some slight adjustments to accomidate my laziness.