Step 9: Custom Box Design
A nice custom box is a great way to finish any project! Unfortunately, fabricating custom boxes is no cake walk. Plans for the box are attached, however should only be used as a general basis for your work. Verify the measurements (and puzzled edges) before starting the laser.
Note: The images attached are not to scale. They give dimensions for a box made from 0.25" acrylic. After a trip to Lowe's, I decided to use 0.08" acrylic instead, so the dimensions were adjusted accordingly when sent to the laser-cutter. Unfortunately, these plans are lost in the ether. You will have to use your judgement with the box design. Access to a drill (or drill press) and a tap set help tremendously. I do not recommend you attempt to cut the smaller holes (3/32") with the laser-cutter - they should be drilled instead.
In the six images provided, seven box pieces are given. One piece is for a horizontal divider inside the box, which is used to stack the Raspberry Pi above the breadboard. Once all seven pieces were cut, the holes should be drilled to the appropriate pilot size and then tapped as noted on the diagrams. Note that the LCD's holes are missing from the face plate, and will need to be added.
Before assembling the sides and bottom, connect the pushbuttons and LCD to the front plate. After this, the four sides and bottom can be assembled using 1-Minute epoxy. I did not use epoxy on the top piece, since I like being able to open the box (hinges or clear tape are both would be a nice choice to connect the top).
Once the sides are assembled, the breadboard should be attached to the bottom using velcro. 1.25" standoffs should be added, then the center piece screwed into these. After connecting the ribbon cable, the Pi should be mounted to the smaller 0.325" standoffs and screwed in place. Secure the top, and the system is complete! Photos of the final product are given in the last step.