docs(shell): size the rear Ethernet, DC and power-button openings - #13
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The shell page named the three rear openings but never gave their dimensions, so there was no way to tell which panel parts fit without opening the STL and measuring it. Measured from the release STLs and identical on Shell-x1202, Shell-x1206 and Shell-x12-a1: - Ethernet: 16.0 x 14.0 mm cut-out, plus two 4.0 mm dia screw holes 27.0 mm apart on the cut-out's horizontal centreline - DC jack: 12.5 mm dia - Button: 12.5 mm dia - The face they sit in is 3.0 mm thick Each opening now lists what to check on a datasheet before ordering: body size, screw spacing and panel-thickness rating for the Ethernet coupler; barrel thread, flange diameter and 5.5 x 2.1 mm socket for the DC jack. The 12.5 mm dia button hole takes a 12 mm momentary button, not the 16 mm button that gets referenced elsewhere, so that is called out. Adds a barrel-jack polarity warning. A 5.5 x 2.1 mm plug has no keying, so a centre-negative supply mates perfectly with a centre-positive jack and reverses the rail into the Pi, the UPS and both radars. The Geekworm X1202 and X1206 are both centre pin positive. Also counts the two M3 screws the Ethernet coupler needs in hardware.md, which the shell hardware table did not list. Co-authored-by: HuggeK <48095810+HuggeK@users.noreply.github.com> Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
The reference models under reference-models/connectors/ came from open-flight#8, where they were contributed as dimensional references for other enclosure projects. The Ethernet one is a round coupler with a 21.7 mm thread, and the v1 shells have no round Ethernet bore at all: an exhaustive sweep of every cut-out in the sloped rear face finds exactly the 16.0 x 14.0 mm rectangle, the two 4.0 mm dia screw holes, and the two 12.5 mm dia round holes. Anyone buying from that model for a v1 shell would get a part that cannot fit, so the page now says so. The DC reference jack is the opposite case and is noted as representative: 11.0 mm dia threaded barrel, 15.5 mm dia flange, 18.5 mm long, which is a correct fit in the 12.5 mm dia hole. Also sources the centre-positive claim. Geekworm's X1202 and X1206 wiki pages do not state the barrel polarity either way, so the page now points at the exchange where Geekworm confirmed it rather than implying the wiki carries it. Co-authored-by: HuggeK <48095810+HuggeK@users.noreply.github.com> Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
The DC jack section said nothing in this build needs soldering, which contradicts Required hardware on the next page over: an iron is needed to heat-set the inserts. The goal is to keep soldering to a minimum, not to reach zero. The advice to buy a pre-wired jack stands on its own. Co-authored-by: HuggeK <48095810+HuggeK@users.noreply.github.com> Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
The 16 mm button is being removed from the project's shared Mouser project, so contrasting against it points at a part nobody will be looking at. The section states the requirement directly: a 12 mm panel-mount momentary push button. Co-authored-by: HuggeK <48095810+HuggeK@users.noreply.github.com> Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
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Read through it - looks fine to me.
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September 22, 2026 19:49
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The shell page names the three rear openings but never gives their dimensions, so there is no way to tell which coupler or jack fits without opening the STL and measuring it. This adds the numbers.
Measured from the release STLs; identical on
Shell-x1202,Shell-x1206andShell-x12-a1:The face all three sit in is 3.0 mm thick — the number most often missed, since many panel connectors are cut for thin sheet metal and will not close on 3 mm of plastic.
reference-models/connectors/Ethernet_Panel_Coupler.stepis a round coupler with a 21.7 mm thread, and thev1shells have no round Ethernet bore at all. Sweeping every cut-out in the sloped rear face returns exactly five — the rectangle, its two screw holes, and the two Ø12.5 mm round holes. Nothing at Ø21.7.That fits how those models arrived (#8 contributed them as references for other enclosure projects), but anyone buying from them for a
v1shell ends up with a coupler that cannot fit. The page now says so. The DC reference jack is the opposite case and is noted as representative: Ø11.0 mm barrel, Ø15.5 mm flange, a correct if slightly loose fit.Polarity warning
A 5.5 × 2.1 mm barrel plug has no keying, so a centre-negative supply mates perfectly with a centre-positive jack and reverses the rail into the Pi, the UPS and both radars at once. The X1202 and X1206 are both centre pin positive — per @JedS on openflight#273, cited because Geekworm's own wiki states it nowhere.
How the dimensions were measured
The openings lie in one sloped rear face, plane
0.85y − 0.52z = 144.3(inner) to147.3(outer), giving the 3.0 mm thickness. Bore-wall triangles inside that slab were clustered by shared vertices and each cluster measured in the face's own in-plane frame; listing every cluster with no size filter is what rules out a missed opening.The Ethernet cut-out resolves to exactly 8 triangles, confirming sharp corners rather than rounded, at 16.00 × 14.00 mm. The round holes come out at Ø12.50 (12.47–12.53 across the facets) and the screw holes at Ø4.00, all through the 3.01 mm wall. Re-running on all three
v1shells returns identical numbers.These are measured from the meshes rather than read off the CAD source, so please sanity-check them against the Fusion model before merging — particularly the 27.0 mm screw spacing, since that is the one a buyer cannot fudge.
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