Pocket Mesh Assembly

Shell Fabrication

This document assumes that all dependencies in regards to tooling, materials, etc. have already been satisfied.

Print STLs, let cool
After removing STLs from print plate, use sharp implement of choice to trim printing supports.
File and sand printing support stubs nearly flush
Paint the entire shell inside and out with acetone slurry (acetone with ABS dissolved in it)
Carefully trim and file SD card cover, and SD card cover slot, such that SD card cover has snug fit in SD card cover slot.
Using a ten millimeter socket, and acetone slurry, smooth out antenna port hole.
File and sand shell for fit and finish.

Battery pack preparation

Important note: Do not have 18650 cells installed in battery pack during these operations.

Sand and file battery pack to fit shell.
Using spudger, remove bottom plate to battery pack. This exposes the circuit board.
Wire red lead to positive USB port pins, bridging ports 1A and 2A ports.
Solder black lead to negative USB pin, only connecting to 2A port.
Terminate red and black leads with correct (solder pin header, 2.54mm) connector.
Cut hole in bottom plate of battery pack in the correct position
Thread power leads through hole in bottom plate. Reattach bottom plate to battery pack.
Affix battery pack to shell permanently (Current approach uses acetone slurry to weld pack to shell)
Set shell assembly aside.

Raspberry Pi preparation

Important note: Do not have 18650 cells installed in battery pack during these operations.

Using soldering station, remove USB port opposite the RJ-45 port on a Raspberry Pi 3, Model B.
Solder the secondary radio leads to the USB contact pads on the Raspberry Pi. Solder the other end o the leads to the secondary radio.
Flip Raspberry Pi over, and solder red lead to PP2, and the black lead to PP3. Terminate these leads with solder pin header female, 2.54mm.
Using thermal adhesive, install heat sinks onto Raspberry Pi in the correct places, making sure to leave clearance for the encryption module.

Assembly

Carefully insert modified Raspberry Pi into shell. Some fitment may be required.
Attach antenna extension cable to wifi radio. Connect other end of extension to shell.
Using M2.5 screws, screw 3d printed standoffs to shell in provided holes, securing the inserted Raspberry Pi between them.
Install encryption module on GPIO pins on the Raspberry Pi.
Insert battery into encryption module.
Test fit shell lid to standoffs. Fitment work as needed.
Screw shell lid in place.