Build Custom Enclosure

The physical profile of this board is too wide to find the off-the-shelf enclosure. So I design the original chassis for this board.

Material and Tools

Raspberry-pi uses Wi-Fi radio feature, so I decided to use wooden side panels for this chassis. All the materials are ready to buy at Home-Center DIY Corner.

• Bronzed Aluminum Bar thickness of 3.0mm (W=40mm, L=300mm, 2pcs)
• Aluminum Panel size of thickness of 2.0mm (100mm x 300mm)
• Aluminum Panel size of thickness of 1.0mm (100mm x 300mm)
• Wooden Panel (Acacia Wood, Rose Wood, Walnut, etc...)
• Chipping Coat Spray Paint (as called "Chassis Black" for the Top Panel)
• Insert Nuts (M4, M3)
• Hexagon Screw (M4)
• Screws and Washers (M4, M3)

Schematic Drawing

Concept Design

Initially, the design was optimized for just-fit size.

Actual CNC Design

Rethinking the combination of other equipment, I changed it to fit the width of another chassis. Nearest sized chassis was 300mm wide.

So I changed the design as follows...

Milling the Face Panels

I used two types of milling-tools

• V-Shape Mill (for Lettering)
• End-Mill 3.18mm (for Drilling holes)

My CNC3018 pro MAX takes one hour for the front and takes more than 5 hours for the rear. The bottom chassis is not necessary to use the PCB fixing post.

Filling Rasin into the LED Indicator Hole

Embedded SMD LED indicator lights will be guided through from the inside to the face panel.
（This photo is the flip side of the Front Panel. You can see the mistaken version ;-)

Filling and making a dip of the UV-Rasin. Another side is masking sealed by tape. You'd better use the syringe for filling.

Building Enclosure

Sidewoods are mounted on the 2.0mm AL Base plate. PCB is hanging between front and rear face panels.

Raspberry-pi Shutdown/Reboot button and DSP Reset button was reverse mounted for debugging only use.