After botching the screen removal from my donor iMac I found a screen (only) on eBay and continued the project using that. Objectives at that point were:
- 5K at 60 Hz main display for Mac mini
- Quiet operation - no fan, no power supply squeal
- Audio - use original speakers with appropriate crossover circuit
- Maintain original look - no drilling, nothing stuck on the outside, keep RAM door intact, use existing AC cord and on/off button
- Have a Plan B
I have no need for built-in webcam (my preference) or USB-C charging.
Display board - R9A18, no fan, 5K @ 60 10-bit with 2 DP cables, 10W audio, comes with remote.
Power Supply - I didn't want to mess with iMac power supply and instead went with power brick.
Control Strip - The existing display On/Off button is spliced in. I mounted Control Strip on back of R9A18 facing case vents so I could potentially use IR remote. Otherwise I could get to the buttons through RAM access door. I've found that I never use the Control Strip.
Audio - I wanted to reuse internal speakers and wire up L and R crossover circuit using auto grade components. Crossover was built on a small perf board. I/O wires were pretty fragile where I soldered them in so I added some terminal blocks bought at local MicroCenter. It sounds good and goes up pretty loud. Thanks to
@PaulD-UK for figuring out the crossover specs.
Video - OWC TB to 2DP splitter mounted internally. I got this idea from
@Kaeslin (Post 1409). A CableMatters right angle USB4 cord comes in through original Ethernet port. I used DP cables with the latching mechanism to lessen likelihood of them coming loose.
Plan B - I can't stand the fact that once you close this up it takes major surgery to access the insides for repair, so I have a few Plan Bs. Currently AC is spliced into the iMac AC wires so I can use the original power cord. If the power supply brick ever goes out I can plug in an external PS through the RAM door. Similarly, if the TB to 2DP splitter ever goes out I can go with an external one and run DP cables through RAM door. Finally, if the audio craps out I can always use external speakers on my desktop. I don't expect any of these things to happen but if they do I can keep using the monitor and just live with the ugly until I feel like opening up the monitor to fix (or not).
I ran it for a couple of weeks with screen held on by painters-tape just to make sure everything was going to hold up. It did, so I put on the adhesive strips and sealed it up. I am very happy with the end result. I feel like this was a prototyping exercise and I find myself thinking about what I'll do when I build "the next one". But for now I'll enjoy this one. Thanks to everyone here for sharing their experiences and creativity.