Prototype Cardboard Case

DRAFT

I either use plexiglass or metal for Raspberry Pi cases. Before committing to these materials, I build a prototype case out of cardboard, and fit all the components. I usually start with paper or index cards and then move to heavier stock stock cardboard. By cardboard, I mean something like the matting used around photos, and not the corrugated cardboard used in boxes.

If I am going to create a lot of the ssame cases, then I will create a template from thin MDF or very thin plywood.

In this project, I am going to create a case that fits inside a Fintie Silicon Case Cover. The cover is designed for a Nest Hello Doorbell.

Dimensions

The Nest Hello Doorbell is approximately:

height = 4-10/16-inches
width = 1-11/16-inches
depth = 1 inch

Step 1. Create the Face Plate

Use note cards to create two roughly cigar shaped face plates for the Fintie Silicon Case Cover. I made a rough sketch by tracing the inside of the Fintie cover and then added about 1/8 inch all the way around.

I put two index cards together; taped them so they wouldn't move, and cut out the sktech. Next, I cut the two pieces so they are a more than 1/2 but less 3/4 the height of cover. The idea is to slide them back-and-forth until snug.

Slip these into the case and slide them until tight. Hold and tape.

Note any changes. Redo as needed until the fit is snug. Then transfer this template to heavier cardboard stock.

I used a compass to get nice half-circle ends

The final faceplate dimensions are:

height = 4-1/2 inches
width = 1-11/16 inches

Create a couple of extras to experiment with the placement of the devices on the face plate.

Step 2. Create the Base Plate

In photographs, the Nest Hello Doorbell doesn't seem to taper as much from front to back as the Fintie cover does.

Use Heavy Cardboard Stock (poster board) or light tin; must be cheap and readily available; toss it when it doesn't work; shouldn't damage the cover; no sharp edges if using tin

pushing the doorbell should put 0 pressure on the electronics. The doorbell struts must sturdy and not wiggle under pressure

Step X1. [optional] Build Prototype Cardboard Case

Use note cards to create two roughly shaped face plates for the Fintie Silicon Case Cover. Cut them so they are a more than 1/2 but less 3/4 the height of cover. Slip these into the case and slide them until tight. Hold and tape. Note any changes until the fit is snug. Then transfer this template to heavier cardboard stock.

Nest Hello Doorbell is 4-10/16-inches tall, 1-11/16-inches wide, and 1 inch in deep.

Use Heavy Cardboard Stock (poster board) or light tin; must be cheap and readily available; toss it when it doesn't work; shouldn't damage the cover; no sharp edges if using tin

pushing the doorbell should put 0 pressure on the electronics. The doorbell struts must sturdy and not wiggle under pressure

The case imposes limitations on what fits inside, and therefore to some extent on what it can do. My approach is to get it to work, and then to figure out how to optimize it (or shrink it).

Pi Zero Dimensions: 66.0 x 30.5mm or 2.6 x 1.2 x 0.2 in.

Both Ring and Remo use Torx screws on the bottom of the box. I don't think it is a big deal if the Torx screws are on the front or bottom of the box.

Fintie Silicone Cover for Nest Hello - fits Pi Zero W

- - 4-11/16 x 1-11/16 x 1 in

Make a face plate and use button and other through hole connectors to secure face plate to structure. Make the structure of bent aluminum to fit gasket and form basis of case. Paint the face plate black. Also make an oval form to keep the gasket in shape.