Building the box
First of all we need to make an enclosure. I decided to make my own cause I didn't find any online. I made mine in oak. I recommend that you don't make the box too small so you can fit the components inside. My box is 16cm deep, 16cm wide and 6.2cm tall on the inside. The wood is about 9mm thick. The holes for the buttons should be 30mm in diameter. If you make the enclosure yourself it might not look exactly the same as mine.
To make the box you are going to need:
- A saw
- A drill with a diameter of 30mm
- A file
- A hammer
- A knife
- A pen
When you have all of these things you can start building it!
1. Cut the wood plates
First of all, cut the wooden plates to a wanted size. I recommend 16x 16x 6.5cm. Then draw out the holes for the buttons on the top plate. Next draw out the holes for the nails on the outer wood plates. When that is done check that everything fits together.
2. Drill the holes
This is the tricky part because when you drill the holes you want to make sure that the wood does not crack. So make sure you keep the plate secure with some nails for example. The wood will crack along the fibers if it cracks.
Before you drill on the wood you are going to use, take a piece of wood you are NOT going to use for this project and drill a test hole with a 30mm drill and see if the button fits. When that is checked drill the 16 holes on the top plate you are going to use.
Don't forget to drill the USB hole as well! Use a small drill for this. If you did forget (like I did) you can drill it later. And after the USB hole is drilled, use a file to make it square.
Good luck! ;)
3. Clean the holes
Take a sharp knife an sandpaper and make the holes rounder and cleaner.
4. Putting everything together
Next up, glue and hammer the nails in the holes on the side plates. When you are done, secure the box and leave it for the night. But don't glue or hammer the bottom plate! Leave the bottom plate for later.
5. Make the corners round (optional)
For the final step on building the enclosure, use a file or sandpaper to make the corners round.