Step 3: Fitting the LCD & PCBs

1 | Measure the spacing between the buttons on the menu board. Transfer these measurements onto the back of the panel and mark out where holes need to be drilled so that the buttons will poke out through the veneer. Double check they are aligned correctly because it will be very difficult to fix if it goes wrong. Drill out the holes from the back with the panel sat on a flat surface.

2 | Fit the menu board into the recess making sure the buttons are correctly sat in the holes. I have used some spare veneer to support the menu board and hold it in place. Two plywood brackets are then screwed over the board to hold it tightly in position.

3 | With the LCD in position glue in four supports, these will be used to mount a brace behind the LCD onto which will go the logic board. I have left a 1mm space between the four supports and the edge of the LCD.

4 | Take note of the position of the logic board and measure out a backing plate to line-up with the previous four supports. Use these measurements to make the backing plate from thin plywood.

5 | Position the logic board so that the flat cable from the LCD is not twisted when inserted into the logic board. You will need to also take into consideration the HDMI cable to ensure there will be enough clearance when in the aluminum upper case. Using a pencil mark the back plate where the screw holes on the logic board will go.

6 | I have glued four additional smaller wood supports over the marks where the logic board holes will go. This will raise the circuit board up so the underside does not foul on the back plate. Make sure you remove the back plate from over the LCD when drilling screw holes for the logic board.

7 | Put some foam strip on the underside of the backing plate, this will help hold the LCD tight in place.

8 | The WiFi card is secured using two wood supports. Two strips of veneer keep the PCB straight, and two screwed on clips hold it tight. You will need to check the underside of your WiFi card for components, they should not foul or rest against the wood.

9 | The much smaller Bluetooth PCB will be stuck on with double-sided sticky foam.
oldmechanic2 years ago
wow! what a nice idea! i might try it out myself with my pi. well done!