(This s a project for your 3D printer. If you don’t have a 3D printer available, write me at firstname.lastname@example.org and I can make them for you.)
I got the original art for the outer housing from Ardusat. Next, I added two plates to hold everything inside the satellite. You’ll need to make two housing end parts, two housing side parts, and two base plates. The artwork for your 3D printer is in a zip file connected to this step.
The base plate has four very small holes in it near the center for a photocell and temperature probe. These may be pretty filled in when the plates are made, but you can easily open the holes with a straight pin or a dental pick. The holes are only needed in the top base plate.
Assemble the outer housing first by snapping the four parts together. Next, using eight of the ⅝” 4-40 screws and nuts, bolt everything together. Don’t over tighten! You don’t want to break the tabs on the parts, although superglue can fix any accidents you have. The picture shows what it looks like when the housing is finished.
Next, mount one base plate on an end part using four 1 ¼” screws and 12 nuts. The idea is to position the base plate near the end of the screws so there is plenty of room on both sides.
Finally, install the second base plate (with the tiny holes opened) underneath the top end plate using four ⅝” screws and nuts. This finishes the complete housing for your demonstration CubeSat!