- Waterproof pelican case
- 3 water proof ports on outside (power, network, USB)
- Raspberry Pi 3B with arch Linux
- 11 Inch Screen (with 5 buttons for control)
- Full cherry keyboard
- Gigabit switch
- USB hub
- 3S2 battery pack with custom charge cable (red port)
- ESP32 with OLED display, 2 rotary knobs, 5 buttons and keypad to control SDR
- 2 External Antenna connectors
- Tray for flipperZero (https://flipperzero.one/)
- Custom sticker on outside
- Custom cut aluminum plates with custom vinyl sticker on top
I decided to add an ESP32 to take input from the keypad, 5 buttons and the 2 rotary knobs. It would also control the single color OLED in the top of the case as well as a planned external color LCD (currently not installed).
The idea is to allow the control of the SDR via the knobs and quickly start a program or enter a frequency either via keypad or rotary knob. Communication with the Pi is not yet defined but maybe via serial port or SPI.
To connect everything up neatly created the following PCB.
The PCB also connected the 5 buttons that control the display (this is just to clean things up). The USB port is not used.
There are two brackets that can be printed. The only difference it the length.
They attach to the case with a 9.5mm long M3 self tapping screw. There is a nut to attach the plate which is able to move in order to account for offset between cases as they are not all exactly the same size.
Make sure the screw does not go more than around 4mm into the case as the case is approximately 5mm thick.
To attach the brackets correctly I would suggest mounting them to the aluminum plate first and then to the case.
I looked into several different options for doing the panels. I wanted them to be sturdy enough for the size of the case but not too heavy either. I initially was looking into acrylic but I found it was too brittle or too thick for what I wanted. Acrylic would have allowed me to back light things from behind which would have been neat.
In the end I went with 2.5mm aluminum which is just thick enough not to flex too much. I had the panels cut by a local shop that lets me get pricing via online calculator. However before I took that step I printed several version of paper and double checked everything is correct. I still meed up the hole site for the interconnect however I was able to drill that out of the correct size. I also had to file down one side of the panel as the Pelican case CAD files are not exact even if you leave a margin. I would suggest you don't get your panels made before you have the case and can measure the actual site of the case.
I used Fusion 360 to make a simple sketch and cut out all the holes I needed. The shop I used (https://blexon.com/) accepted the exports from Fusion and let me pick the material.
I am extremely please with the results from the metal shop and I have used them in other projects as well. Highly recommend.
For the print I went the simple route and exported the file into Inkscape where I designed the look of the panels. I then exported this to a PDF and had it made into a vinyl sticker by a local sticker maker. Biggest pain was trying to get the large sticker perfectly right on the panel. Next time I would add some markers on areas that are cut out anyway to make it easier to align.