Weatherproof case build

[ltorsini]

Hi All,

I thought I would post a few shots of the weatherproof case I've been working on over the last week or so - 2gig with all the bells and whistles. From a hardware perspective everything went together very well, I'll be adding a cell card, the photo/temp/humidity sensors and the zwave when it arrives.

Software with Android is slow and buggy, haven't started tuning on it yet so any advice is welcome at this point.

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I used a template of the screen to scribe the dimensions of only the backlit portion of the screen into a Dykem outline painted on the cover

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A rounded nose end mill to cut the outline of the screen into the housing

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The cover face is sturdy enough with the ribbing to allow you to cut almost fully through from the interior

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Carefully realign the cover face up and finish removing material from the face

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Only the active portion of the screen should be visible when you've finished trimming

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I used 1/8 x 1/4 3M car window sealing ribbon to mount the screen, be sure to align it well before it makes contact, once it is on it will never come off in one piece and it will never leak

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It is a pretty close fit but the screen nestles under the acrylic mounting board without being in direct contact which should keep it from overheating, note the backup battery mounted to the acrylic plate

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The ribbon cables for the camera and screen are just long enough to reach when mounted, the metal bracket on the right holds the camera in place over its view hole in the cover

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Removing the cover from the PoE splitter allowed will allow you to machine the case for a tight fit, use black silicone RTV to secure it to the case and screen

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I've split out the speaker and mic ports and flush mounted them to the case, you can see the PoE splitter to the very right

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The battery leads are just long enough to glue the battery to the door of the case using a high temperature non expanding adhesive

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Depending on how the battery temperature looks as the unit cycles, you can use the material removes for the screen as a heat exchanger to improve cooling and battery life

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You can see the front mount camera view hole to the left of the screen, be very careful on it's placement to minimize stress on the ribbon

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I also added two sealed microswitches by milling down the existing bolt hole bosses and threading them in from the back, these are the on and reset buttons

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Final product has handle/wall mount and an improved wireless antenna.  The external antenna made a big difference in the performance of the wireless card