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Docs Build & Assembly Building Your Own Case

Building Your Own Case

Edit on GitHub

Design a custom enclosure from scratch: layout, cutouts, antenna exit and assembly

Building Your Own Case

Overview

Beyond the Hammond 1593L and the ready 3D models, a custom case lets you tune the layout to your exact parts. This page covers the design decisions.

Internal Layout

Order the modules to minimize interference:

  1. Battery at one end, away from the antenna.
  2. Radio module at the antenna end, SMA at the exit.
  3. OLED on the display face.
  4. GPS patch facing up with clear sky view.
  5. Audio jack on the side opposite the SMA.

Dimensions

ModuleApprox footprint
ESP32 DevKit V155 x 28 mm
E22-400M30S25 x 20 mm
SSD1309 2.42” OLED60 x 37 mm panel
TP405625 x 17 mm
NEO-6M25 x 25 mm
1865065 x 18 mm

Cutout Checklist

  • OLED window
  • USB-C
  • 3.5 mm audio jack
  • 4 buttons
  • 2 LEDs
  • SMA

Antenna Exit

ChoiceNotes
SMA bulkheadCleanest, needs a hole + nut
Direct whipStrain relief required
Internal vertical whipOnly with a non-metal case

Assembly Order

  1. Mount and wire the power path (battery, TP4056, ESP32).
  2. Verify boot and battery reading.
  3. Add OLED and verify the screens.
  4. Add radio + antenna, verify TX with a dummy load.
  5. Add GPS, verify a fix outdoors.
  6. Seal and label the frequency plan on the outside.