Rosewill RSV-R4100U Replacement Front Panel

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This is a replacement front panel for the Rosewill RSV-R4100U server chassis. The original panel only allows for a single intake fan and front mounted 5.25" drives/accessories. This replacement panel will allow for mounting 3x120 mm fans retaining the original USB plugs. Also included is a mounting bracket to be able to reuse the 3.5" drive bay that comes with the unit.

BOM:
M3 screws - assorted lengths

M3 inserts - 6mm or less

M2 countersunk screws and nuts

12mm push button - make sure it's not a latching one

Fans

Printing:

• Panels and bracket:
  • 6 walls
  • 15% gyroid infill
• Fan cover:
  • You'll definitely want to use a smooth plate and glue as a release agent or the infill will likely break. Make sure you let the build plate cool down before trying to remove.
  • This is semi-customizable. You can adjust the infill pattern and density of the “Fan Cover Mesh” object to change the mesh design to whatever you want.
    • 6 walls for the frame
    • 4 walls for the mesh
      • 24% rectilinear infill

Remove OE Front Panel:

1. Remove the top cover.
2. Remove the two cages.
3. Remove the mounting ears (3 screws each).
4. Drill out the rivets:
   1. There are two under each handle
   2. Four along the bottom front edge
   3. Two on the bottom, perpendicular to the front at about the mid point (these hold a bracket for the two cages.
5. Pull the front panel off and remove the OE bracket.

Assembly Front Panel:

1. Two M3 screws to join the two front panels using the tabs at the top and bottom.
   1. 15-20mm long screws
2. Two M3 inserts into the round mounting tabs for the USB ports.
3. Attach the USB ports using m3 screws.
4. Attach all three fans.
5. Add your power switch. 

Assembly - Mounting Bracket:

1. Just add M3 inserts to each hole.

Assembly - Fan Covers:

1. Each hole gets a 10x2mm magnet.

Installation:

1. Slide the front panel on. The power button should be in the bottom right when facing the chassis.
2. Use M2 screws and nuts where the rivets were to attach the front panel.
3. For the mounting bracket, use two m3 screws from the bottom to mount it standing up. The wider part of the mount is the top.
4. Add the 3.5" drive cage back in. Reuse the factory screws for the outer bracket and M3 screws for the inner side on the 3D printed mount.
5. Readd the mounting ears if desired. I opted to throw a nut onto the screws since there's hardly any thread engagement through the thin sheet metal.
6. I opted to cut and splice the button wires to the motherboard headers that came with the case. The polarity doesn't matter. You could also crimp them, use a level nut, twist them together with some electrical tape (not recommended), make a magnetic connector, etc..