Fork me on GitHub

Make a case for a Raspberry Pi Radio

laser cutter | cardboard and scissors

Remove [old instructions](https://github.com/radiodan/project/blob/master/docs/case_construction.md)

This guide describes how to make a case, providing templates for a laser cutter and for a hand-made version in cardboard.

The case is designed (by Victor Johannson) to be something that can be changed and adapted to the size of different components.

Here we use a USB soundcard and a 5cm diameter speaker, but we’ve also experimented with versions with cheap miniature speakers instead, though in that case you may need to increase the number of corner pieces and make the side pieces wider (and the sound won’t be as good).

It’s also designed to be laser cut in 3mm acrylic or MDF, but we have made versions successfully in cardboard, although the button press movements mean that the top piece and supporting side bar need to be quite stiff (see below).

First, make your Raspberry Pi radio.

Radiodan laser-cut box: What you’ll need

  • a Raspberry Pi Radiodan with wifi
    • a suitably provisioned SD card
    • a USB wifi card, RT5370 chipset
    • a USB-powered sound card
    • a 5cm diameter speaker soldered to a 3.5mm audio jack
    • buttons and dials - see this tutorial (you can make the case without first).
    • 4 x 3mm diameter bolts, 4cm or more in length, and 4 wingnuts or similar
    • 2 x 5mm diameter nuts to fit 2 short 2mm diameter screws to hold in the Pi
    • power supply for the Pi
  • access to a laser cutter with a least an A3 bed
  • superglue
  • an A3 sheet of 3mm acrylic

Radiodan laser-cut box: Steps

Laser cut the pieces

Use our case template.

Assemble the base

Add the four bolts and the two internal mounts. Play particular attention to the placement of the arrows - they should point to the circular hole.

Step 1: base

Glue the nuts to the internal mount

Glue the nuts into the mount first. The mount fits both the model B and the new B+, but you need to glue the nuts into different holes depending on your model. The B+ holes are identified with a plus sign. It’s easier to apply the glue to the holes, situate the screws in rough position on a flat surface and then manouver the internal mount piece over the top.

Step 2: glue the nuts to the internal mount

Add three of the edge pieces, the corner pieces, and the internal mount

When the glue is set, fit the mount into the box, slotting it into the side pieces.

There are 8 corner pieces on each corner.

The four edge pieces just slot in.

Step 3: edges and corners

Add the wifi card, SD card and power supply to the Pi

Don’t plug the Pi in yet.

Put the wifi card in the bottom USB slot.

Assemble the Raspberry Pi and perpherals

Put the Pi in the box

missing image

Secure it with the screws and the rubber washers.

If you have a model B+, the USB ports will be on the other side.

Add the speaker

missing image

The speaker should sit tightly in the hole.

Attach the speaker’s 3.5mm jack to the sound card, and the sound card into a USB port

Add the speaker mount

missing image

It fits tightly into the gap between the internal mount and the side pieces, and holds the speaker in.

Add the back of the case

missing image

Using the butterfly screws, and feeding the power cable through the hole in the back of the case.

Enjoy your Radiodan

missing image

Next steps

You may want to add some buttons and dials


First, make your Raspberry Pi radio.

Radiodan cardboard box: What you’ll need

  • a Raspberry Pi Radiodan with wifi
    • a suitably provisioned SD card
    • a USB wifi card, RT5370 chipset
    • a USB-powered sound card
    • a 5cm diameter speaker soldered to a 3.5mm audio jack
    • buttons and dials - see this tutorial (you can m$
    • 4 x 3mm diameter bolts, 4cm or more in length, and 4 wingnuts or similar
    • 2 x 5mm diameter nuts to fit 2 short 2mm diameter screws to hold in the Pi
    • power supply for the Pi
  • superglue
  • an A3 sheet of corrugated or thick cardboard
  • scissors or a knife and something suitable to cut on
  • a hold punch that will fit your cardboard
  • some paper with a nice design on it

Radiodan cardboard box: Steps

Do everything

missing template and writeup

Example cardboard Radiodan

Next steps

You may want to add some buttons and dials