So I just posted the pictures to Google+ and of course wanted to post them to my site as well, and of course in much better detail.

I just wanted something easy to take apart, and didn’t cost alot because I knew my friends would want one. (I’ve built 3 now, and more people keep asking..) and was strong, as I do alot of running around, and project fairs.

This has turned out better then I had expected, and am really quite pleased. It starts with a few off the shelf parts (I got mine from Lowes) and consist’s of:

  • (2) PVC Romex Handy Box Covers (with the knockout option)
  • (4) Nylon 1/4″ x .104 x 1″ spacers (two packs of two)
  • (4) 6-32 x 1 1/2″ Pan Head Steel Bolts (one bag of eight, I’ve got extras)
  • (optional) Spray Paint, Rounded 6-32 end caps (Pictured at the end)
Let’s start by getting the nylon spacers painted. lightly nail them upright into a scrap of wood, and then paint them.
Next I knocked out the hole on the box cover that was to be the top, and then cleaned up the edges with a razor knife and some sandpaper.
(this is part of the reason to go with PVC covers, it drills and cuts MUCH easier and is softer so it won’t hurt it if you go too tight during assembly or need to clean up an edge with a razor knife.)
You’ll notice I have notched the bottom part. This is to allow room for the SD Card to lay flat. I did this by melting through most of the way (from the back side) with an old soldering iron, and then trimming down the sides with a razor knife. I also melted the flange on the stock holes to allow it to sit as deep as possible in the bottom cover (and yes I did this before painting.)
Here’s the parts, ready for assembly!
(The heat sinks are about ten bucks at Frys and are for RAM if you were wondering)
It’s important that the holes next to the USB ports allow the spacers to sit close to the sides of the USB ports. This case relies on the flange at the end of the USB ports to help hold the Pi in place. Also put this side together first. It’s just easier.
(see how nicely those small flanges will keep the Pi from sliding out! Perfect!)
And that’s about it! Here’s some more pictures of the final product, and a copy of the reciept from Lowes, in case it might help you find the same parts.