Build Guide

Warning

This guide is a work in progress. Content may be incorrect or missing. Contributions are welcome.

Download STL Files

⬇️ Download CommCrate_v0.1.zip - Contains all STL files ready to print

Overview

This is a proof of concept for a modular emergency communications (EMCOMM) go-kit. The goal of this project is to make a kit that can have equipment swapped out easily without having to fabricate a new top panel. New modules can easily be modeled and implemented without impacting other components. The panel layout can also be moved between different size cases with minimal work.

Key Features:

Modular Design - Swap equipment without redesigning the entire panel
Case Agnostic - Move layouts between different case sizes with minimal work
Non-Destructive - No drilling or permanent modifications to cases
Interoperable - Uses standard Powerpole connectors for compatibility

While this guide uses specific interior components such as the travel router and Meshtastic node, these are only for demonstration purposes. It is up to the user to decide what equipment they should put into the case to serve their specific use case.

Photo of final build

Design Principles

This system follows several key design guidelines:

External Power - Uses external 12V power via Powerpole connectors (not internal batteries)
Powerpole Standard - All 12V connections use Anderson Powerpole in RRTT orientation (Red-Right, Tongue-Top)
Standard Dimensions - Modules are 100mm wide (or 50mm for center panels), heights in 50mm increments
3mm Top Panels - Ensures consistent mounting across modules
Friction-Fit Borders - Case-specific borders hold modules without permanent modifications

Important: All Powerpole connectors must follow the RRTT standard: when looking at the front of the connector with the tongue pointing up, red (positive) should be on the right and black (negative) on the left. This ensures compatibility with standard amateur radio equipment.

Not Covered In This Guide

This guide is primarily concerned with building the internal support structure, the module enclosures, and the electrical wiring. This guide does not cover:

How to setup Raspberry Pi as an ATAK server - The author uses and recommends OpenTakServer
Building or configuring Meshtastic nodes
Travel router setup and programming

Supported Cases

Border pieces are available for:

Pelican 1400 - Premium waterproof case
Strongway 13" - Budget-friendly alternative

New borders can be designed for other cases while reusing all internal modules.

Print Parts

Modules

Tip

Print top faceplates facing down on the build plate to ensure they have a consistent, smooth texture.

Modules are the enclosures for individual components. Each module typically consists of a top and bottom piece that snap together. Print quantities depend on your specific configuration.

File Name	Description	Qty
Mdoule-CenterPanelTop-Ethernet2-SMA2.stl	Center panel top with 2 Ethernet ports and 2 SMA connectors	1
Module-CenterPanelBottom.stl	Center panel bottom piece	1
Module-FanTop.stl	Fan module top cover	2
Module-FanBottom.stl	Fan module bottom mount	2
Module-NetworkSwitchTop.stl	Network switch enclosure top	1
Module-NetworkSwitchBottom.stl	Network switch enclosure bottom	1
Module-PowerPanelTop.stl	Power panel top with switch/connector cutouts	1
Module-PowerPanelBottom.stl	Power panel bottom	1
Module-RaspberryPiTop.stl	Raspberry Pi enclosure top	1
Module-RaspberryPiBottom.stl	Raspberry Pi enclosure bottom	1
Module-SwitchBoxTop.stl	General purpose switch box top	1
Module-SwitchBoxBottom.stl	General purpose switch box bottom	1

Structure

Structural components form the internal framework that holds everything together. These parts create a modular grid system.

File Name	Description	Qty
Structure-Connector4WayCross.stl	4-way cross connector for rail intersections	6
Structure-Connector5WayCross.stl	5-way cross connector for rail intersections	5
Structure-ConnectorSlidingL.stl	Sliding L-shaped connector for adjustable corners	4
Structure-ConnectorSlidingT.stl	Sliding T-shaped connector for adjustable joints	4
Structure-Rail35mm.stl	35mm rail segment	8
Structure-Rail65mm.stl	65mm rail segment	14
Structure-Rail85mm.stl	85mm rail segment	25
Structure-RailMount57mm.stl	57mm mounting bracket	2
Structure-RailMount80mm.stl	80mm mounting bracket	1
Structure-RailMount88mm.stl	88mm mounting bracket	1

Borders

Border pieces provide mounting points and support for specific case types. Choose the borders that match your case. Print the borders facing down on the build plate.

File Name	Description	Qty
Pelican1400-BorderSide.stl	Side border for Pelican 1400 case	As needed
Pelican1400-BorderTop.stl	Top border for Pelican 1400 case	As needed
Rack-Strongway13inFrameLeft.stl	Side frame border for Strongway 13" rack	As needed
Rack-Strongway13inFrameTop.stl	Top frame border for Strongway 13" rack	As needed

Assembly

Foundation

The foundation of the crate consists of 3D-printed rails, connectors, and mount.

The diagram below shows how to arrange the parts to form the foundation. The left and right arms using the sliding L and T connectors allow the crate to easily be adjusted to fit varying sized cases.

Diagram of rails, connectors, and mounts

Note: This diagram has an error with the 80mm Mount placement. The 80mm Mount should be moved over to the 65mm on its right.

Mounting Gear

Mount the Powerpole Distribution Block to the 88mm Mount using two M4x10 screws.
Mount the DC 12V to 5V Converter to the left 57mm Mount using two M4x10 screws.
Mount the Terminal Strip Block to the 80mm Mount using two M5x10 screws.
- Cut red and black barrier strips in half and insert them into one side.
- Ensure the cut ends of the barrier strips are facing away from each other to prevent accidental contact.
Mount Meshtastic nodes on the center rails with zip ties.
Mount the travel router to the right 57mm Mount with zip ties.

Mounted gear

Wiring the Foundation

This section covers how the core power and data wiring is laid out on the foundation: the 12 V Powerpole distribution, 5 V distribution, DC‑DC converter, Meshtastic node, router/switch, and future fan/switch modules.

All 12 V power uses Anderson Powerpole (PP) connectors. 5 V devices are fed from a central 12 V‑to‑5 V converter.

      Power Module (built later)
    (PP port, fuse, master switch)
                 │
                 │ Powerpole
                 ▼
    ┌─────────────────────────┐
    │  Powerpole Distribution │
    │         Block           │
    │    (+12V / 0V buses)    │
    └─────────────────────────┘
                      │        │
        ┌─────────────┘        └───────────────┐
        │                                      │
        ▼                                      ▼
 ┌──────────────┐                    ┌──────────────────┐
 │  12V → 5V    │                    │   12V Devices:   │
 │  Converter   │                    │                  │
 └──────────────┘                    │  • Switch Box    │
        │                            │  • Netgear Switch│
        │                            │  • Fan (Left)    │
        ▼                            │  • Fan (Right)   │
 ┌──────────────┐                    └──────────────────┘
 │ 5V Terminal  │
 │    Block     │
 │ (+5V / GND)  │
 └──────────────┘
        │
        ├──────────┬───────────┬────────────┐
        │          │           │            │
        ▼          ▼           ▼            ▼
  Raspberry Pi  Meshtastic  Travel    (Future 5V
     (USB-C)      Node     Router     devices)
               (USB-C)    (USB-C)

Powerpole Distribution Block Preparation
- The Powerpole distribution block will receive power from the Power Module (which you'll build later with the panel mount Powerpole connector, fuse, and master switch).
Tip: Use ~22 AWG wire for the low‑current runs shown here. Size up if you plan to add higher‑draw loads later.
12 V to 5 V Converter
- From the 12 V bus, run:
  - +12 V (red) from below the Powerpole distribution block (where switch box will go) to the input + terminal of the 12 V‑to‑5 V converter.
  - 0 V (black) from the Powerpole distribution block to the input – terminal of the converter.
- This converter now provides a regulated 5 V rail for the Raspberry Pi, Meshtastic node, and travel router.
5 V Distribution Block
- On the output side of the converter, run:
  - +5 V (red, 22 AWG) from the converter + output to the + bus on the 5 V distribution block.
  - 0 V (black, 22 AWG) from the converter – output to the – bus on the 5 V distribution block.
- All 5 V devices home‑run back to this block so they share a common ground with the 12 V system.
Future Switch Box and Fan Modules (12 V)
- Pre-wire for a future 12 V switch box and fan modules so they can just plug in later.
- Switch box feed
  - From the 12 V side of the converter (same point as the converter input), run a +12 V lead down to the area where the switch box module will sit.
  - Terminate this lead with a red Powerpole. This will be the main 12 V feed into the future switch box.
- Common negative for fans
  - From the converter's negative (or the 12 V negative bus), run a 0 V lead to the Powerpole distribution block, if it isn't already tied in.
  - From that common negative, split off two 0 V leads:
    - One to the bottom‑left Powerpole pair.
    - One to the bottom‑right Powerpole pair.
  - These negative Powerpoles will be used by the future fan modules.
- Positive for fans
  - From the switch box area, run a single +12 V lead that connects to both fans:
    - Terminate with a red Powerpole at the bottom‑left fan location.
    - Continue the wire to terminate with a red Powerpole at the bottom‑right fan location.
  - This creates a total of 3 red Powerpole connectors: one for the switch box feed and two for the fans.
  - Each fan module will get +12 V from this daisy‑chained wire and 0 V from the distribution block.
Powering the Network Switch and Router
- Netgear switch (12 V)
  - Cut the original DC barrel connector off the Netgear power cable to create a pigtail.
  - Identify the positive conductor (usually marked) and crimp/solder it to a red Powerpole contact.
  - Connect the negative conductor to a black Powerpole contact.
  - Plug this new Powerpole pigtail into:
    - Positive: the same +12 V point that feeds the future switch box.
    - Negative: any 0 V position on the Powerpole distribution block.
- 5 V devices (Pi, Meshtastic node, travel router)
  - Use USB‑C (or appropriate) pigtails for each device.
  - For each pigtail:
    - Tie the +5 V wire into a separate position on the +5 V bus of the 5 V distribution block.
    - Tie the ground wire into the – bus of the 5 V distribution block.
  - Route:
    - One pigtail to the Raspberry Pi location.
    - One pigtail to the Meshtastic node.
    - One pigtail to the travel router.
RF and Ethernet Routing
- Attach an SMA pigtail to the Meshtastic node's RF connector and route it to the center where the antenna will mount on the center panel.
- Run two Ethernet cables from the travel router:
  - One from the WAN port.
  - One from the LAN port.
- Dress these cables to the center panel area so they're ready to plug into the center panel module.

Wiring

Switch Module

The switch box provides four individually switched 12 V outputs on Powerpole connectors for controlling fans, 5V converter, Netgear switch, and other 12 V devices.

Required Parts:

Module-SwitchBoxTop.stl (face plate)
Module-SwitchBoxBottom.stl (cage)
4 × toggle switches with safety covers
4 × M4 × 10 mm screws
Wire for daisy-chaining 12 V common and creating switched outputs
5 × Anderson Powerpole pairs (4 for outputs, 1 for input)

Assembly:

Install switches in face plate
- Place the top face plate face-down.
- Insert the four toggle switches into the cutouts from the front.
- Install switch covers and secure with mounting hardware (nut/washer).
Wire the common 12 V feed
- Bring the +12 V input wire (from the Powerpole distribution block) into the cage.
- Connect to the input terminal of the first switch.
- Daisy-chain the +12 V across all four switches using short jumper wires.
- This ensures all switches share the same 12 V source on their input side.
Note: Ground/negative does not go through this box. All negatives stay on the main Powerpole distribution block.
Create switched Powerpole harnesses
- For each switch:
  - Connect a switched +12 V lead to the output terminal.
  - Use a different wire color (yellow recommended) to distinguish switched +12 V from common +12 V.
  - Crimp both wires to an Anderson Powerpole pair:
    - Red wire = common +12 V (connects to the daisy-chained input side of the switch)
    - Yellow wire = switched +12 V (connects to the output terminal of the switch)
- You'll have four Powerpole harnesses, one per switch, ready to plug into 12 V loads.
- Device ground/negative wires connect directly back to the Powerpole distribution block, not through these harnesses.
Close the enclosure
- Place the wired face plate onto the bottom cage, tucking wires carefully.
- Align the four corner holes.
- Install M4 × 10 mm screws and tighten evenly.

Switch module

Power Module and Adapter

The power module provides the main power entry point with panel-mount Powerpole connector, inline fuse protection, and a master LED toggle switch. The 12V power adapter is also modified with Powerpole connectors for easy connection.

Required Parts:

Module-PowerPanelTop.stl (faceplate)
Module-PowerPanelBottom.stl (cage)
Panel-mount Powerpole connector
Panel-mount fuse holder with 15A glass fuse
Red LED toggle switch (master power)
4 × M4 × 10 mm screws
Wire (22 AWG red/black)
Anderson Powerpole connectors and contacts
Heat shrink tubing

Assembly:

Install hardware in faceplate
- From the front, insert the panel-mount Powerpole port, fuse holder (without fuse), and master toggle switch into their respective cutouts.
- Secure from the rear with supplied nuts/retainers.
- Orient the toggle so "ON" is in your preferred direction.
Wire the power path
- Positive (+12V) chain: Run red wire from PP port (+) → fuse holder input → fuse holder output → toggle switch input → toggle output (terminate with red PP connector for distribution block feed).
- Ground (0V): Run black wire from PP port (–) directly to a black PP connector (for distribution block return). Add a short branch to the toggle switch LED ground terminal.
- Install the 15A fuse in the holder.
Verify before mounting
- Use a multimeter to confirm continuity: PP port (+) → fuse → toggle → output PP (+).
- Confirm PP port (–) → output PP (–) and toggle LED ground.
- Verify no continuity between +12V and ground.
Mount the module
- Place the wired faceplate into the bottom cage.
- Align mounting holes and secure with four M4 × 10 mm screws.
- Ensure wires have slack for strain relief.
Adapt the 12V power supply
- Cut off the original DC barrel connector.
- Strip and tin the leads; identify polarity with a multimeter.
- Crimp Powerpole contacts: red housing for +12V, black for ground.
- Add heat-shrink tubing over the cable/PP joint for strain relief.
- Test: plug adapter into wall and measure voltage at the PP pair to confirm polarity and voltage.

Power module

Fans

The fan modules provide active cooling with one fan configured for intake and one for exhaust, creating airflow through the enclosure.

Required Parts (per fan):

Module-FanTop.stl (faceplate with grill)
Module-FanBottom.stl (cage)
80mm 12V cooling fan
4 × M4 × 10 mm screws (for cage assembly)
4 × fan mounting screws (typically included with fans)
Anderson Powerpole connectors and contacts
Wire strippers and crimping tool

Assembly:

Prepare fan power leads
- Cut off factory connectors from each fan, leaving maximum wire length.
- Strip 5–6 mm (¼") of insulation from the red and black wires.
- Crimp Powerpole contacts onto each wire: red = positive, black = negative.
- Insert contacts into PP housings until they click. Tug gently to verify they're fully seated.
Mount fans to faceplate
- Position the first fan under the faceplate, checking the airflow arrow on the fan housing.
- Place the grill on top of the faceplate over the fan opening.
- Secure fan and grill with the included fan screws (snug, not overtight).
- For the second fan, flip orientation so one fan intakes and the other exhausts.
- Repeat mounting process for the second fan.
Close the enclosure
- Align the faceplate with the bottom cage.
- Secure with four M4 × 10 mm screws at the corners.
- Verify fans spin freely and grills don't contact blades.

Note: Connect fan Powerpole connectors to the pre-wired harnesses from the foundation wiring (controlled by the switch box).

Fans

Network Switch

The network switch module houses the Netgear 5-port Gigabit switch, providing wired network connectivity between the Raspberry Pi, travel router, and external devices.

Required Parts:

Module-NetworkSwitchTop.stl (faceplate)
Module-NetworkSwitchBottom.stl (cage)
Netgear 5-Port Gigabit Switch
4 × M4 × 10 mm screws

Assembly:

Prepare the switch
- Ensure the Netgear switch has its Powerpole power pigtail already attached (from the foundation wiring step).
- Verify any needed Ethernet cables are connected to the appropriate ports.
Install the switch
- Hold the faceplate and cage together, aligned.
- From the bottom, slide the Netgear switch up into the cage.
- The switch is held in place by friction fit—gently push until it's fully seated and flush with the faceplate.
- Ensure power and network cables have adequate slack and aren't pinched.
Secure the enclosure
- Align the faceplate with the bottom cage.
- Install four M4 × 10 mm screws at the corners and tighten evenly.
- Verify the switch sits securely and doesn't rattle.

Network switch

Center Panel

The center panel module provides external connectivity for the system, featuring two Ethernet ports for network access and two SMA connectors for RF antenna connections.

Required Parts:

Module-CenterPanelTop-Ethernet2-SMA2.stl (faceplate)
Module-CenterPanelBottom.stl (cage)
2 × Category 5E panel-mount Ethernet jacks
2 × SMA female-to-female bulkhead adapters
4 × M3 machine screws with nuts (for Ethernet jacks)
4 × M4 × 10 mm screws (for cage assembly)

Assembly:

Install the Ethernet panel-mount jacks
- From the front side of the center faceplate, insert the two Ethernet (Cat5e) panel-mount jacks into their cutouts.
- Align the mounting holes in the jacks with the holes in the faceplate.
- Secure each jack using M3 machine screws with matching nuts:
  - Insert the M3 screws from the front of the plate.
  - Place a nut on the back side and tighten until snug.
  - Do not overtighten.
Install the SMA panel-mount feed-throughs
- Insert the two SMA female-to-female bulkhead adapters through the lower round holes in the faceplate from the front.
- On the rear side, install the supplied SMA bulkhead washer(s) and nut(s).
- Tighten the SMA nuts with a small spanner or needle-nose pliers until the adapters are secure and do not rotate.
Attach the center faceplate to the cage
- Align the assembled center faceplate with the matching opening in the cage.
- Start all four M4 × 10 mm screws by hand through the corners of the faceplate into the cage.
- Once all four screws are started, tighten them evenly in a criss-cross pattern until the faceplate is firmly seated against the cage.
- Verify that the Ethernet ports and SMA connectors are centered in their openings and not under mechanical stress.

Center panel

Raspberry Pi Module

The Raspberry Pi module as the ATAK server.

Required Parts:

Module-RaspberryPiTop.stl (faceplate with port cutouts)
Module-RaspberryPiBottom.stl (cage with standoffs)
1 × Raspberry Pi board (Pi 4 or Pi 5 recommended)
4 × M2.5 screws (for mounting Pi to standoffs)
4 × M4 × 10 mm screws (for cage assembly)

Assembly:

Mount the Raspberry Pi into the bottom cage
- Place the bottom cage on the table with the flat side down.
- Orient the Raspberry Pi so its HDMI, Ethernet, and USB ports line up with the openings in the faceplate/cage (HDMI should be toward the side where the large round HDMI cutout is).
- Gently lower the Pi onto the holes inside the cage.
  - The mounting holes in the Pi should sit directly over the holes.
- Fasten the Pi to the cage using the 4 × M2.5 screws (or the screws provided with your Pi).
  - Start each screw by hand to avoid cross-threading.
Position the ports in the faceplate
- With the Pi now fixed in the cage, slide the connector end of the cage assembly into the faceplate from behind.
- The Pi's HDMI port should sit directly behind the HDMI opening in the faceplate.
- Make sure all front connectors (HDMI, Ethernet, USB) are centered in their cutouts and can be easily accessed from the front.
Secure the cage to the faceplate
- Keep the faceplate facing outward and hold the cage firmly against its back.
- Insert the 4 × M4 × 10 mm screws through the mounting holes in the faceplate and into the matching threaded holes in the cage.
- Start all four screws loosely first, then tighten them evenly in a cross pattern so the faceplate seats flat against the cage.

Raspberry Pi module

Final Assembly

With all of the individual modules wired and assembled, it's time to bring everything together into the finished go-kit.

Prepare the Rail Supports
- Ensure 85mm rails are inserted into all the connectors on the foundation.
Install the Modules and Borders
- Starting from one side, slide the first border panel into the rail supports, aligning the edges with the grooves.
- Insert the first module next to it, keeping light pressure on both sides so it tracks straight in the rails.
- Continue alternating modules and border pieces across the width of the crate.
- As you go, check that:
  - No cables are getting pinched behind the panels.
  - Connectors, switches, and fans sit flush and aren't binding on the rails.
Cable Clearance Check
- Flip the crate carefully and confirm that all internal wiring has enough slack and that nothing is under tension.
- Verify that fans spin freely and that all ports and switches are accessible from the front.
Drop the Crate into the Case
- Open the Pelican case fully and remove the foam.
- With the lid open and facing away from you, lift the completed crate assembly and lower it straight down into the case.
- Ensure the crate sits flat on the bottom, with no cables or hardware trapped under the frame.
- Check the front edge to confirm that the panel face is centered and that the lid can close without touching any controls or connectors.
Final Fit and Closure
- Close the lid slowly the first time, watching for any interference. If you feel resistance, stop and adjust the crate position.
- Once the lid closes cleanly and the latches engage without extra force, the final assembly is complete and ready for use.

Final assembly

Parts List

Tools

Item	Qty	Notes	Source	Link
Precision Screwdriver Set	1	For M2.5, M3, M4 fasteners	Amazon	Link
Powerpole Crimping Tool	1	For Anderson Powerpole contacts	Amazon	Link
Assorted Crimp Terminal Kit	1	Automotive-style screw terminals	Amazon	Link
Wire Cutters/Strippers	1	For cutting and stripping wire	Amazon	Link
Multimeter	1	For testing continuity and voltage	Amazon	Link
Needle-Nose Pliers	1	For tightening SMA connectors	Amazon	Link

Power & Protection

Item	Qty	Notes	Source	Link
Power Supply 12V 3A	1		Amazon	Link
Powerpole Panel Mount Connector	1	Multiple options available	Amazon	Option 1 • Option 2 • Dual Port
Powerpole Distribution Block	1		Amazon	Link
DC 12V to 5V Converter	1	Sold as 2-pack	Amazon	Link
Glass Fuse 15A 20mm	1		McMaster-Carr	Link
Panel Mount Fuse Holder	1		McMaster-Carr	Link

Switching & Controls

Item	Qty	Notes	Source	Link
Red LED Toggle Switch	1	Sold as 2-pack	Amazon	Link
Toggle Switch 12V	4	Sold as 6-pack	Amazon	Link

Cooling

Item	Qty	Notes	Source	Link
Cooling Fans 80mm 12V	2	Sold as 2-pack	Amazon	Link

Networking & Connectivity

Item	Qty	Notes	Source	Link
GL.iNET GL-SFT1200 (Opal)	1		Amazon	Link
Netgear 5-Port Switch	1		Amazon	Link
Category 5E Panel Mount Adapter	2		McMaster-Carr	Link
HDMI Panel Mount Adapter	1		Amazon	Link
USB C Pigtails	3+	Sold as 5-pack	Amazon	Link
Ethernet Cables	4+	Various lengths for internal routing	Amazon	⚠️
Meshtastic Nodes	1+	Optional - only if using Meshtastic	Various	-
Raspberry Pi 5 Kit	1		Amazon	Link

RF / Antenna

Item	Qty	Notes	Source	Link
915 MHz Whip Antenna	1		Amazon	Link
SMA Panel Mount Female to Female Connector	2	Sold as 10-pack	Amazon	Link
SMA Male to SMA Male Cable, 6 inch	2	Sold as 4-pack	Amazon	Link

Termination, Wiring, and Fasteners

Item	Qty	Notes	Source	Link
Terminal Block and Strip	1	Sold as 2-pack	Amazon	Link
Assorted Powerpole Connectors	?	Sold as assorted pack	Amazon	Link
Assorted Wiring	1	22 AWG red/black/yellow wire	Amazon	Link
Heat Shrink Tubing	1 set	Various sizes for wire strain relief	Amazon	Link
Zip Ties	1 pack	For mounting nodes and router	Amazon	Link
M2.5x6 Screws	4	For mounting Raspberry Pi	McMaster-Carr	Link
M3 Machine Screws with Nuts	4	For Ethernet panel mount jacks	McMaster-Carr	⚠️
M4x10 Screws	100	For module assembly	McMaster-Carr	Link
M5x10 Screws	2	For the 5V distribution block	Amazon	⚠️

Case

Item	Qty	Notes	Source	Link
Pelican 1400 Case	1	Option 1 - Premium waterproof case	Amazon	Link
Strongway 13" Water-Resistant Storage Case	1	Option 2 - Budget-friendly alternative	Northern Tool	Link

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Build Guide

Download STL Files

Overview

Design Principles

Not Covered In This Guide

Supported Cases

Print Parts

Modules

Structure

Borders

Assembly

Foundation

Mounting Gear

Wiring the Foundation

Switch Module

Power Module and Adapter

Fans

Network Switch

Center Panel

Raspberry Pi Module

Final Assembly

Parts List

Tools

Power & Protection

Switching & Controls

Cooling

Networking & Connectivity

RF / Antenna

Termination, Wiring, and Fasteners

Case

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