Lite Kit

AMSAT CubeSatSim Lite Kit

These instructions show how to take an AMSAT CubeSatSim Lite and put it in a frame and run it from a USB power pack.

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Parts

You can make your CubeSatSim Lite look like a real CubeSatSim with these additional parts to make a CubeSatSim Lite Kit:

You will need:

• A fully assembled CubeSatSim Lite with micro USB power cable.
• USB Power Pack that fits inside the frame https://avidopower.com/product/avido-cube-2600mah-pocket-sized-smart-portable-power-bank-charger/
• small piece of velcro to attach power pack to frame.
• Short micro USB to USB cable https://www.amazon.com/dp/B0BXYDNS7C/ref=dp_iou_view_item?ie=UTF8&th=1
• 6" long SMA coax cables https://www.amazon.com/Yuslao-Bulkhead-Extension-Receiver-Cellular/dp/B0FDJQBT6S or (2) https://www.digikey.com/en/products/detail/taoglas-limited/CAB-01043/25550308 with SMA Nuts (2) https://www.digikey.com/en/products/detail/te-connectivity-linx/NT-SMA-G/12821517 and SMA Lock Washers (2) https://www.digikey.com/en/products/detail/te-connectivity-linx/WS-SMA-G/12821516
• Frame (4 parts) https://github.com/alanbjohnston/CubeSatSim/tree/master/hardware/frame/v2.0 (Note: you don't need the part plug_circle_24.stl as it is a RBF plug)
• Digikey parts including the following:
• 23mm standoffs (2) https://www.digikey.com/en/products/detail/raf-electronic-hardware/M2118-2545-SS/10073382
• 11mm + 6mm standoffs (2) https://www.digikey.com/en/products/detail/raf-electronic-hardware/M2106-2545-AL/7681435
• M3 plastic screws for frame (8) https://www.digikey.com/en/products/detail/50M030050P012/145-50M030050P012-ND/11639796
• M3 plastic nuts for frame (8) https://www.digikey.com/en/products/detail/709940300/732-12637-ND/9488341
• M2 plastic screws (2) for the camera https://www.digikey.com/en/products/detail/essentra-components/50M020040P012/11638163
• M2 plastic nuts (2) for the camera https://www.digikey.com/en/products/detail/essentra-components/04M020040HN/9677098

Video

Here's a Video of this.

Steps

Start from a fully assembled CubeSatSim Lite

Next, remove the SMA antennas and unplug the micro USB power cable:

Flip the Lite upside down and unscrew two of the screws into the Pi Zero 2W. Make sure it is the two that are away from the GPIO header, as shown here:

Screw together the 23mm standoff and the 11mm standoffs:

Attach these standoffs to where you removed the two screws:

Here's a closeup:

Press the M3 nuts into the slots in the frame top and bottom:

Here's how they look when they are installed:

The two screws you removed earlier will attach the frame to the two standoffs you attached. Place the bottom frame as shown here:

Secure with the two screws:

Plug in the short micro USB power cable as show:

Attach the two SMA cables as shown:

Next, we will attach the frame top:

Remove all the hardware from the SMA cables and poke them through the frame top holes:

Secure with a washer and nut. If there are two washers, only use one.

Next, we will attach the side frame with camera. Make sure the frame isn't upside down:

The Pi Camera will attach to the frames with 4 M2 screws and nuts. I have used hot glue to attach the nuts to the camera so that they stay in place. If you do this, be careful not get any glue in the threads:

Here's how the Pi Camera looks from the back when attached.

Here's how it looks from the outside:

The frame side is secured using two M3 screws:

Here's how the side looks when attached:

Next, attach the other frame side using two M3 screws:

Here's how it looks attached:

The USB power pack is attached with two small pieces of velcro that are attached to the bottom of the power pack and stuck to the frame bottom:

Put the top down by bending the SMA cables.

Attach the SMA antennas:

Plug the USB power cable into the USB power pack to power up the Lite:

Here's how it looks from all sides:

Your build is complete!