Step 8: Assembly & Cables

1 | Drill holes in each corner of the Raspberry Pi's mount & the USB mount. I added an extra hole in the centre of the Pi's mount. You don't have to be too exact at this stage.

2 | I put the Raspberry Pi, complete with its card and headphones-out cable, positioned it where I wanted it to sit inside the case, with the SD Card close to the edge so it doesn't fall out, and then drilled through the previous holes into the case. This should give exact holes which you can now use to fit screws to hold the support in situ.

3 | Widen the holes and use a counter-sink bit in a drill to bevel the holes. Be very careful as the thin aluminum can split & tear easily. Check that the screw heads sit flush with the case.

4 | Fit the template into the case and screw down, refit the Raspberry Pi to check all is ok.

5 | Do exactly the same with the USB hub. I have fitted the receiver for the keyboard towards the case edge. The edge should help retain the receiver but it is best to leave a 1mm gap to absorb any knocks to the side.

6 | Find a spare space for a switch, measure its dimensions and cut a slightly smaller hole into the wood panel. Because I don't want the toggle of the switch protruding above the panel it will need to be mounted lower down then usual. I would recommend using the same process as used when fitting the keyboard to create a recess where the switch will fit. Being a bit of a numpty I didn't think to do that until after I had cut the hole!

7 | Yes, I know it looks a bit like a face. It gives it some character!

8 | The panel mount RJ45 socket was pulled from an old PC. I had to solder on some CAT5e cable, and then protect the socket with some heat-shrink.

9 | Measure the size of the RJ45 socket. Transfer the measurements onto the case where you would like the socket to fit. I used a Dremel cutting disk to start cutting out the hole for the socket. I then finished the hole with a sharp blade.

10 | The end of the socket is surrounded with a wooden bracket. The bracket puts the socket level with the edge of the case.

11 | Wire up the headphone socket to the headphones plug from the Raspberry Pi. Check you have the channels the right way round. Fit the cable into the case.

12 | The RJ45 socket is glued in against the side of the case. There is enough room for a screw toward the top if you think it needs one. It really depends on which socket you have.