From 04e7a2038a37cb234414a72d4a3cfd38f292e9df Mon Sep 17 00:00:00 2001 From: "Claude Opus 5 (1M context)" Date: Tue, 22 Sep 2026 19:40:33 +0200 Subject: [PATCH 1/4] docs(shell): size the rear Ethernet, DC and power-button openings 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) --- docs/hardware.md | 6 ++++ docs/parts/shell.md | 82 +++++++++++++++++++++++++++++++++++++++++++-- 2 files changed, 85 insertions(+), 3 deletions(-) diff --git a/docs/hardware.md b/docs/hardware.md index ef15cf0..2d8edbe 100644 --- a/docs/hardware.md +++ b/docs/hardware.md @@ -31,9 +31,15 @@ Same on every current `v1` shell (Ethernet, DC jack, power button). Old USB-C re | 2 or 4 each | M2.5 insert | Each of **3 Adafruit module bays** you populate (skip empty bays) | | 10 | M3×8 / M3×10 / M3×12 | Mount screen + lower front to the shell | | 4 | M3 insert | **Adjustable feet only** — omit if using solid feet | +| 2 | M3 screw + nut, or M3 self-tapper | **Ethernet coupler only** — the flange screws into the two Ø4.0 mm rear holes, 27.0 mm apart. No insert: the holes are clearance, not insert pockets | Adafruit total if all three bays are used: **6 or 12** extra M2.5 inserts (2 or 4 per bay). +The rear DC jack and power button clamp into their own Ø12.5 mm holes with the +nuts they ship with — no screws or inserts. See +[Rear I/O openings](parts/shell.md#rear-io-openings) for every rear hole +dimension and what fits it. + ### Screen bezel | Variant | M3 inserts | diff --git a/docs/parts/shell.md b/docs/parts/shell.md index 0063fc5..c55e4ee 100644 --- a/docs/parts/shell.md +++ b/docs/parts/shell.md @@ -2,14 +2,90 @@ The rear body. Pick one board-specific file. Every current `v1` shell has the same rear I/O: -- **Ethernet** through the rear -- **Barrel DC jack** for power -- **Power button** +- **Ethernet** — 16.0 × 14.0 mm opening with two Ø4.0 mm screw holes +- **Barrel DC jack** — Ø12.5 mm +- **Power button** — Ø12.5 mm + +Full dimensions and what fits them: [Rear I/O openings](#rear-io-openings). USB-C rear shells are **EOL** (USB-C spec compatibility) — see [`stls/shell/eol/`](../../stls/shell/eol/README.md). ![Pi and UPS mounted in the shell](../drawings/assy-01-boards.png) +## Rear I/O openings + +Every current `v1` shell carries the same three openings on one sloped rear +face, so these numbers apply to `Shell-x1202`, `Shell-x1206` and +`Shell-x12-a1` alike. + +**The face is 3.0 mm thick.** That is the panel thickness a threaded connector +has to clamp, so check that each part's panel-thickness range covers 3 mm +before you buy it. Many panel connectors are cut for thin sheet metal and will +not close on 3 mm of plastic. + +| Opening | Size | Centre (model X) | +| --- | --- | --- | +| **Ethernet** | **16.0 × 14.0 mm** rectangular cut-out (16.0 across the shell, 14.0 up the face), plus **two Ø4.0 mm screw holes 27.0 mm apart**, on the cut-out's horizontal centreline | 40.0 mm | +| **DC power** | **Ø12.5 mm** round | 73.0 mm | +| **Power button** | **Ø12.5 mm** round | 161.8 mm | + +All three centres sit at the same height on the face. Across the 200 mm-wide +shell they run Ethernet, then DC jack, then power button: 33.0 mm from the +Ethernet centre to the DC centre, and 88.8 mm from the DC centre to the button +centre. Measured from the release STLs. + +### What fits the Ethernet opening + +A **panel-mount RJ45 feed-through coupler with a two-screw flange** — the kind +that takes a patch lead on each side, not a punch-down keystone. Check three +numbers on the datasheet before ordering: + +1. the part of the body that passes through the panel is **no larger than + 16.0 × 14.0 mm**; +2. the flange screw holes are **27.0 mm apart** and take **M3** screws — the + shell's Ø4.0 mm holes are clearance, so an M3 screw with a nut behind, or an + M3 self-tapper into the plastic, both work; +3. it is rated for a **3 mm** panel. + +The [reference model](../../reference-models/connectors/Ethernet_Panel_Coupler.step) +in this repo is a generic stand-in drawn to check fit. It carries no +manufacturer part number, so no specific product is endorsed here — match the +three numbers above instead. + +### What fits the DC opening + +A **panel-mount DC barrel jack** with: + +- a threaded barrel of **Ø12 mm or less** — the common 12 mm-thread panel jack + is the snug fit; an M11 jack also goes in, with 0.75 mm of slop per side that + its flange covers; +- a **flange or bezel wider than Ø12.5 mm**, so it seats against the face; +- a **panel thickness rating that reaches 3 mm**; +- a **5.5 × 2.1 mm** socket, if you are feeding a Geekworm X1202 or X1206 — + that is the barrel size those boards use. + +Buy one that comes **pre-wired with a flying lead**. Nothing in this build +needs soldering, and a jack with solder tags would break that. + +> [!WARNING] +> **Barrel-jack polarity — get this wrong and you can destroy the Pi, the UPS +> and the radars at once.** A 5.5 × 2.1 mm plug carries no keying: a +> centre-negative supply mates perfectly with a centre-positive jack and +> reverses the rail. The Geekworm **X1202 and X1206 both expect centre pin +> positive (+)**. When you wire the panel jack, the **centre/tip contact goes +> to +** and the sleeve to −, and the supply you plug in must also be centre +> positive. Check the jack's own pinout with a multimeter before the first +> power-up rather than trusting wire colour. The openflight +> [power guide](https://github.com/open-flight/openflight/blob/main/docs/get-started/power.md) +> covers the wiring end to end. + +### What fits the button opening + +A **12 mm panel-mount momentary push button** — Ø12.5 mm is a 12 mm button +hole, not a 16 mm one, so the widely referenced 16 mm buttons do **not** fit +this shell. It must be **momentary** (spring-back): the X1202/X1206 read how +long the button is held, so a latching or toggle switch will not work. + ## Board-specific shells | Board | STL | From 9ee7d1381d3bebff3a3dfdf9b25ecee06282d7fb Mon Sep 17 00:00:00 2001 From: "Claude Opus 5 (1M context)" Date: Tue, 22 Sep 2026 19:50:14 +0200 Subject: [PATCH 2/4] docs(shell): flag that the reference Ethernet coupler does not fit v1 The reference models under reference-models/connectors/ came from #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) --- docs/parts/shell.md | 30 ++++++++++++++++++++++-------- 1 file changed, 22 insertions(+), 8 deletions(-) diff --git a/docs/parts/shell.md b/docs/parts/shell.md index c55e4ee..eadcce5 100644 --- a/docs/parts/shell.md +++ b/docs/parts/shell.md @@ -47,10 +47,15 @@ numbers on the datasheet before ordering: M3 self-tapper into the plastic, both work; 3. it is rated for a **3 mm** panel. -The [reference model](../../reference-models/connectors/Ethernet_Panel_Coupler.step) -in this repo is a generic stand-in drawn to check fit. It carries no -manufacturer part number, so no specific product is endorsed here — match the -three numbers above instead. +> [!NOTE] +> **Do not buy from the reference model for this opening.** +> [`reference-models/connectors/Ethernet_Panel_Coupler.step`](../../reference-models/connectors/Ethernet_Panel_Coupler.step) +> is a **round coupler with a 21.7 mm thread**, contributed in +> [#8](https://github.com/open-flight/openflight-enclosure/pull/8) as a +> dimensional reference for *other* enclosure projects. This shell has no +> round Ethernet bore at all — its opening is the 16.0 × 14.0 mm rectangle +> above — so that part does not fit a `v1` shell. Match the three numbers +> instead; no specific product is endorsed here. ### What fits the DC opening @@ -67,15 +72,24 @@ A **panel-mount DC barrel jack** with: Buy one that comes **pre-wired with a flying lead**. Nothing in this build needs soldering, and a jack with solder tags would break that. +Unlike the Ethernet one, the +[reference DC jack](../../reference-models/connectors/DC_5.5x2.1_Panel_Jack.step) +is representative: it is a round jack with an Ø11 mm threaded barrel behind an +Ø15.5 mm flange, 18.5 mm long overall. That drops into the Ø12.5 mm hole with +0.75 mm of slop per side, which the flange covers. + > [!WARNING] > **Barrel-jack polarity — get this wrong and you can destroy the Pi, the UPS > and the radars at once.** A 5.5 × 2.1 mm plug carries no keying: a > centre-negative supply mates perfectly with a centre-positive jack and > reverses the rail. The Geekworm **X1202 and X1206 both expect centre pin -> positive (+)**. When you wire the panel jack, the **centre/tip contact goes -> to +** and the sleeve to −, and the supply you plug in must also be centre -> positive. Check the jack's own pinout with a multimeter before the first -> power-up rather than trusting wire colour. The openflight +> positive (+)** — confirmed by Geekworm in +> [this exchange](https://github.com/open-flight/openflight/pull/273#issuecomment-5779406632); +> their wiki pages do not state it either way, so do not go looking there. +> When you wire the panel jack, the **centre/tip contact goes to +** and the +> sleeve to −, and the supply you plug in must also be centre positive. Buzz +> the jack out with a multimeter before the first power-up rather than +> trusting wire colour. The openflight > [power guide](https://github.com/open-flight/openflight/blob/main/docs/get-started/power.md) > covers the wiring end to end. From b9d6f9e4cdcd021f16a5f103d888d141672169a5 Mon Sep 17 00:00:00 2001 From: "Claude Opus 5 (1M context)" Date: Tue, 22 Sep 2026 20:13:20 +0200 Subject: [PATCH 3/4] docs(shell): stop claiming the build needs no soldering 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) --- docs/parts/shell.md | 6 ++++-- 1 file changed, 4 insertions(+), 2 deletions(-) diff --git a/docs/parts/shell.md b/docs/parts/shell.md index eadcce5..787b911 100644 --- a/docs/parts/shell.md +++ b/docs/parts/shell.md @@ -69,8 +69,10 @@ A **panel-mount DC barrel jack** with: - a **5.5 × 2.1 mm** socket, if you are feeding a Geekworm X1202 or X1206 — that is the barrel size those boards use. -Buy one that comes **pre-wired with a flying lead**. Nothing in this build -needs soldering, and a jack with solder tags would break that. +Buy one that comes **pre-wired with a flying lead**. This build keeps soldering +to a minimum, and a jack with solder tags adds a joint you would otherwise not +have to make. You will still need an iron for the heat-set inserts, as +[Required hardware](../hardware.md) says. Unlike the Ethernet one, the [reference DC jack](../../reference-models/connectors/DC_5.5x2.1_Panel_Jack.step) From d2dff2369a566ebf7274639dbe08b5acc31e62a9 Mon Sep 17 00:00:00 2001 From: "Claude Opus 5 (1M context)" Date: Tue, 22 Sep 2026 20:14:46 +0200 Subject: [PATCH 4/4] docs(shell): drop the 16 mm button comparison 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) --- docs/parts/shell.md | 7 +++---- 1 file changed, 3 insertions(+), 4 deletions(-) diff --git a/docs/parts/shell.md b/docs/parts/shell.md index 787b911..048dfe6 100644 --- a/docs/parts/shell.md +++ b/docs/parts/shell.md @@ -97,10 +97,9 @@ is representative: it is a round jack with an Ø11 mm threaded barrel behind an ### What fits the button opening -A **12 mm panel-mount momentary push button** — Ø12.5 mm is a 12 mm button -hole, not a 16 mm one, so the widely referenced 16 mm buttons do **not** fit -this shell. It must be **momentary** (spring-back): the X1202/X1206 read how -long the button is held, so a latching or toggle switch will not work. +A **12 mm panel-mount momentary push button**. It must be **momentary** +(spring-back): the X1202/X1206 read how long the button is held, so a latching +or toggle switch will not work. ## Board-specific shells