Step 6 : The enclosure



Download this cutout pattern and cut it on the line. This will fit into the recess on top of the enclosure. (picture shows the underside. Place pattern on top) Note the center bosses measurements and set the pattern accordingly. After you are done with the holes, you will need to remove these two center bosses.
Drill the large LEDs holes with a #8 drill bit.(if you do not have one then a 13/64 will do, it's .004 bigger though) Drill the small LED holes with a #32 drill bit.
The power switch and DC jacks must be placed as close to the top as possible, and place them like in the picture in relation to the verticle PCB slots. Keep in mind if you use a DC jack that the body will be bigger than the hole, so account for it. The holes for the switches and RJ45's can be done various ways, A dremel tool with a 1/16 drill bit will work, or drill a hole and razor blade the rest out, are a couple ways. I have access to a CNC so that is what I used. If you have access to one, the DXF files for the tester and mobile unit holes and board holes, along with the profile cut files can be downloaded here


The cutout pattern for the Mobile unit is here. Print it and cut it out along the line and place it on the inside of the enclosure lid.

Step 7 : Finishing Touches

Now we can install the switches and DC jack. Find a piece of foam 3/8" thick for a battery pad. A couple dabs of hot glue works well to hold it place.
If you used the 4-40 PCB stand offs, you will need five 1/4" 4-40 screws. I couldn't find them that short, so I cut some down. I used a 4-40 tap to thread the bosses, then ran a 4-40 screw into them to finish out the threads to the bottom. The stand offs have to be seated with the bosses when screwed in.
Plug in the connectors. The wires will need formed a bit to clear things and fit well.

After it is assembled, use a known good patch cable and check it's operation.

Step 8 :