Although my previous repair was perfectly fine from a functionality point of view, I was far from satisfied with it. Could I trust it with my data, or better yet, could I trust it to not burn my house down? It was still running much too hot for comfort, and the smell of the hot glue against the caps melting did little to reassure me.
I went hunting for an appropriate solution that would resolve all of my concerns and issues in a single fix.
The solution was provided to me by LaCie. Their power supplies have typically been terrible, but I had no issue with their Porsche series drive power supplies made by Jentec Technology Co. They're very common, very versatile power supplies capable of supplying both 5v and 12v on individual pins with up to 2A of output per rail. The connector is a standard MiniDIN 4 connector, identical to the ADB port on the back of one of our vintage Macs or an S-Video / S-VHS connector, making the connector easy to acquire locally.
Not only did it fit the bill perfectly, it resolved the limitations and shortfalls of the Time Capsule's factory fitted Flextronics power supply.
I understand that the MiniDIN fitting overhangs the USB port. I have decided that even if I have to cut off the tab covering the USB port and fasten it to the case with only one, it will still be rigid enough to support it in the case and withstand connections and disconnections. The screw on the right wing will tap through not only the polycarbonate, but also the metal inner frame, and be secured on the opposite side with a nut of the same size. It should be in there fairly tightly.
The challenge was making it work. I had to bypass the factory power supply entirely, taking the power directly off the connector and into the Logic Board. The method I followed was to reuse the connectors off the factory power supply (I had a second, damaged power supply I could scavenge these connectors from) and connect them via a custom made cable harness to the corresponding pins on the MiniDIN connector. Green is 12v, Red is 5v and Black is GND. All the wires are soldered, heat-shrinked, twisted and cable tied, which makes it a very rigid but reliable cable harness. It's possibly one of my better custom-made pieces.
The entire rig, including power supply, looks a little something like this.
Following the modifications, the Time Capsule now lacks both its power supply and its cooling fan. The increased length of the MiniDIN 4 connector means that the power inlet now intrudes on the space the fan previously occupied. However, as the Time Capsule still has convection cooling for the hard drive, and the primary heat source has since been removed from the unit, this unit now runs cold to the touch, negating the need for the otherwise useless fan entirely.
The ultimate question is though - Does it work?
That little green light makes this all worthwhile.
What's next for the Time Capsule? This week, I hope to bore out the size of the power connector opening on the back and drill supporting screw holes in the case to mount the MiniDIN 4 jack and make it sit flush with the rear of the unit. In the near future, as this Time Capsule is now without its rubber base, I hope to paint the base with a layer of Primer Grey and some lower profile rubber feet to give it that factory appearance. Finally, I hope to christen it with a shiny new 1TB or 2TB internal hard drive.
Mic. (PS. I will be cross-posting the information in this thread to the MacTalk Australia forums shortly.)