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Making a Case/Enclosure for the Khadas Tone Board

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Just checked prices for 3D printing in my Country (Poland) and it is ~25 Euro - the same price than aluminium box from audiophonics.fr
Go metal

 

g29

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Do you have the CAD files so other people can manufacture it too?
HTH. Also see the bottom of the first post of this thread on page one.

https://docs.khadas.com/toneboard/HardwareDocs.html

Hardware Documentation

These documentation files contain hardware information for the Khadas Tone Board.

 

maxxevv

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Do you have the CAD files so other people can manufacture it too?
Its not an off the shelf product.
Doesn't mean that its a free-for-public-domain either.

And what reason is there for you to be asking about something I clearly put a lot of time and effort into for free - as your first post here on ASR? Entitled much?
 
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Its not an off the shelf product.
Doesn't mean that its a free-for-public-domain either.

And what reason is there for you to be asking about something I clearly put a lot of time and effort into for free - as your first post here on ASR? Entitled much?
Whoa there, I just really really liked the design and i thought you didn't share the 3D models because you thought not allot of people had access to the tool required to make it so no one would ask. At my uni we have allot of CNC machines and stuff so I would be able to manufacture. I didn't mean to offend. If you don't want to share thats fine with me. I got excited and started designing my own case any ways. I'm just waiting for my board to come in so i can test fit the first plastic prototype
 
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Its not an off the shelf product.
Doesn't mean that its a free-for-public-domain either.

And what reason is there for you to be asking about something I clearly put a lot of time and effort into for free - as your first post here on ASR? Entitled much?
Here is a teaser ;)

Some feedback would be appreciated as well

ToneBoard Teaser.jpg
 
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Looks really nice. Do YOU plan to share the CAD files? ;)
And what REaSon Is THeRe fOR yOu to BE ASKinG abOUt SOMETHinG i CleARlY pUt A lot oF TiMe And EFfORT inTo FOR FrEe?
No, just kidding.

Yes I am. I'm just waiting for my Tone Board to come in so i can 3D print a prototype of the bottom half so i can make sure all the holes fit correctly and everything is ok.
 

maxxevv

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Obviously you have the means to model what you want. So why the ask for freebie angle in the first place ?

Your design is probably alright for 3D printing but its not exactly "economical" to machine, considering the number of alignment settings I see that need to be done just to get the features you want out of it. Ask a seasoned machinist and you'll see what I mean.
 
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Obviously you have the means to model what you want. So why the ask for freebie angle in the first place ?

Your design is probably alright for 3D printing but its not exactly "economical" to machine, considering the number of alignment settings I see that need to be done just to get the features you want out of it. Ask a seasoned machinist and you'll see what I mean.
Is it that wrong that I genuinely liked your design?
IDK what to tell you
 
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Ok so update, I found one workshop that gave me a quota on making it and they said it just needed som minor adjustments to be able to make but one piece would cost €300. Which you know... is not cheap. I might redesign it ro make it easier to CNC or not well see but for now I have to focus on Uni work for a couple of days
 

maxxevv

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Ok so update, I found one workshop that gave me a quota on making it and they said it just needed som minor adjustments to be able to make but one piece would cost €300. Which you know... is not cheap. I might redesign it ro make it easier to CNC or not well see but for now I have to focus on Uni work for a couple of days
It cost a bit more than what I was expecting. But still ....

In any case, the thing about keeping machining costs down is to minimise the number of work piece alignments / set-ups needed to get the machining done on a 3-axis CNC machine. From what I can see of yours, in the picture/rendering you provided, it will take 6 settings to get it completely machined, assuming that's the top cover and you have a flat lower cover.

Which is why it was quoted at such a price to you. A few tweaks will allow you cut that down to 3 (just the cover alone) , though the aesthetics might need to be altered to achieve that.
 
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nice !

i have a smaller metal case that i am about to use; thanks for the template, which will be helpful

given the overall height of my box is less, and the stand-off mounts will be too long for purpose, i intend to macguyver some m2 nylon mounts that i have "borrowed" from a set for drone stacks

is grounding something i should still attempt to provide ?

i can run a lead from the board to one of the case screws, but happier to keep it simple


fwiw, my current "box" is a box :) (see below)

it was initially a gift packaging for a small ceramic item, and obviously has no earth attachment to the "case" and works transparently wrt sound from the nad d3020 it feeds

IMG_2760.JPG
IMG_2761.JPG
 
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inspired by the prospect of an audiophile-worthy enclosure, i set to work

the parts list (things i had to purchase) :
prices will vary by the day, but for my purchase late august 2019 it was $11.24usd delivered, for both the box and drill required


things i had in my model making stash :
  • diamond edge micro files
  • rat tail and flat file
  • o-rings
  • m2 stand-off spacer kit
  • a suitable electric drill and quick clamps

i used a glue stick to attach the template to my end plate, making sure it was centred, and that there appeared to be adequate clearance given the box i chose was smaller than TimW's original build

gouged the centre marks with a dental tool, and then drilled pilot holes for the step drill with a 1/8" bit

then quick clamped the end plate to a thick piece of scrap wood and set at it free-hand with the step drill till it was at the 12mm mark; likewise to the appropriate diameter for 3 holes where the usb-c opening goes, as per suggestion

some filing to adequate clearances, a tidy up of the exposed edge in the usb slot with a black sharpie as suggested

i could fit an o-ring over each rca, topped with the supplied gold washer, which supplied adequate clearance for the usb "step"

o-rings.jpg


the metal stand-offs supplied with the khadas are too long for purpose in this case, and i elected to support the rear of the board with nylon m2 stand-offs which are usually used for stacks in small drones

they too were too long, as there is a step in the floor of the case

simplest solution was to invert the stand-off, lock it in with the nylon hex nut supplied, and clip it to length with side cutters - a bit of a guess to correct height, but it worked out perfectly (you can see the top view in the picture above)

stand-off.jpg


all that remained was to slide on the top and attach all the screws in their respective chamfered holes, and plug it in

there's no dedicated earth (which is still possible, but is of no obvious importance given i'm listening to it now and the sound is gorgeous)

the box is surprisingly hefty; the completed project weighs 238gm (just over half a pound), making it stable despite the weight of the attached cords, and making it feel like a serious (though petite) piece of kit

i am vacillating on adding feet, but the small silicon half domes would be my choice if i do, but out in the living room it is more convenient standing it vertically next to the amp

i can drill a hole in the front to display the l.e.d., but it's pointless for my tastes - it will only be on when the source is connected, and i disabled the light on that (the htpc) because lights are an annoyance

the rear connectors look damned professional for my first ever metal work project :D

back panel.jpg


and serendipitously, the footprint is a doppelgänger for my (somewhat dusty) headphone amp

stack.jpg


all in all i'm pretty pleased with myself for the effort
 
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Ok so the 3D prints came out good and the Tone board came in as well and everything seems to fit properly. I am in talks with a bunch of Chinese manufacturers trying to make this thing happen but i haven't gotten a quote under $140 even with the changes that they have suggested to reduce costs.

However the biggest cost seems to be that I'm just requesting one. So if enough of you want this case then we can make a group buy and might be able to get a good deal on it. Should i do a group buy post? Please give feedback on this.

Also in addition to the Step files i have attached images of the construction and some beauty renders.
I was trying to go for the RAMA WORKS look but obviously i have some learning to do

Tone_Board_v13_case_for_real_2019-Sep-20_03-59-33PM-000_CustomizedView4578481630_jpg.jpg
 

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Thought I would add my version of the case. Thanks @TimW for the work put into the guide. Given the templates and parts information already listed out, it turned into an easy project I think anyone can manage.

I made a couple of modifications compared to the original post. I purchased Lexan (8"x10"x.093" @ $5) and acrylic (8"x10"x.08" @ $4) from Lowe's as end plates (I also found the exact nylon washers here as well). I ended up using the acrylic since it's a bit thinner and the piece isn't really used structurally. Lexan/polycarbonate should work fine (possibly affecting the spacing a bit more compared to the original aluminum ends). Since the end plate is now transparent, I wanted to have all 3 nylon spacers on the RCA connectors. I had to trim down the outsides of the middle spacer on each side but that was pretty easy.

The hole isn't cut perfectly for the USB connector but it works and it's not noticeable once it's plugged in. That's fine by my standards.

Here's the photos:
IMG_20190920_132624.jpg

IMG_20190920_132605.jpg IMG_20190920_132651.jpg IMG_20190920_132712.jpg IMG_20190920_132828.jpg IMG_20190920_071903.jpg

I apologize for the dust. I did the best I could haha.
 
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you did better re the dust than i did

i was too pleased with finishing that i was keen to document it, and between poor ambient lighting, needing the flash, and old eyes, i didn't see the dust till i pulled up the images on the 25" monitor, and then i figured they showed what i wanted to display ... and dust

my box has no grooves on the large flat areas or sides, which i prefer - maybe because it matches the panam more closely ?

must say that the quote of $140 for an enclosure is beyond my discretionary spending o_O that's almost another khadas and a half :D and above the total cost of my solution including the tone board

as a sculpture i think it looks great; but i reckon it would collect a lot of dust here :facepalm:
 
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