Raspberry Pi 5 On-Body Cyberdeck Case

Please comment or message me for questions!! :)

This is pretty much a closed project but I am open to suggestions if anyone has them!

Ingredients:

• Raspberry Pi 5 (8gb or 16gb recommended but any will fit based on use case)

• Geekworm X1202

• 18650 cell x4 compatible with x1202 (non protected)

• 52Pi EP-0246

• M.2 NVMe 2230/2242 compatible with ep-0246

• Geeekpi Ultra thin Ice tower cooler

• Arducam Hawkeye (i think any pi cam with a v1 or v2 footprint will fit)

• 24.5x1mm watch glass

• Momentary button 12mm dia.

• Keyed switch 12mm dia.

• JST XH2.54-2p connector with leads

• 10cm 24g wire

• Usb-c panel mount extender (this is a fairly specific part im sorry)

• 40mm fan grill

• 1.85x5.18x.1in acrylic panel (requires hand fitting)

3d printed (I used PLA+ but most rigid filaments should work)

• "Top" -x1

• "Bottom" -x1

• "Plug" -x1

Hardware:

Stainless steel

Metric Cap Heads

• M2.5x25 -x5

• M2.5x20 -x2

• M2.5 washer -x7

• M3x16 -x2

• M3x6 -x2 (button hex caps is what i used)

Hex Cap

• M4x16 -x2

• M4 fender washer -x2

• M4 flat washer -x2

• M4 nylock nut -x2

Other materials:

• #2x1/4in flat head wood screw Zinc plated -x5

• #6 flat washer Nylon -x2

• M2.5 brass heat-set insert -x5

• M3 brass heat-set insert -x2

• One-hole d-ring picture hangers -x2 (the hole needs to fit the m4 bolt, otherwise just some way to hang a shoulder strap)

Optional:

• Noctua NF-A4x10 5v PWM 4pin -x1

• JST-SH 1.25mm 4pin -x1

• m2.5x12 or m2.5x10 -x4 to attach the new fan

• adhesive bumpers for the bottom

• Hot glue to fill hole in "Plug" piece

• potentially something like a guitar strap will work if you install guitar buttons on the side instead of the d-rings, i have not tested this

Follow the instructions in the screenshots to add the brass and stainless hardware in the correct places.

Tip: Put a dot of hot glue on the rear of the hole in the "Plug" and let it cool for a moment then push it into the hole so that it is filled with a uniform blob to act as a diffuser for the power light on the EP-0246.

Follow the instructions for the x1202, ice tower, and EP-0246 to attach the Pi5 together. Its probably a good idea to install the camera ribbon cable before the heatsink but it is doable after. 

Tip: If you are going to use a third party fan, you will need to change the connector to a JST-SH 1.25mm 4pin. They are very finicky and it took a few tries for me to get it. Your mileage may vary but i used green-black-blue-yellow for my color pattern on the Noctua from left to right. I don't know if this is right but seems to be fine so far.

Slot the usb-c panel mount extension into the corresponding slot on the "Bottom" part. Slide the "Plug" in over top and tighten two m3x16 cap head screws into the "Plug" from the back and into the threaded portion of the usb-c extension. Wrap the cord around the NVMe card support column as shown.

Fit this assembly into the "Bottom" and plug the usb extension into the x1202 power port then tighten the two m2.5x25 cap heads on the bottom of the "Bottom" into the threaded inserts on the x1202. Next, screw a #2x1/4 screw into the extra hole on the EP-0246, then install the 2242 card over it. If you are using a 2230 card then skip this step and install the card normally.

The camera module should only go into the "Top" one way for the holes to line up for 4x #2x1/4 screws to hold it on securely. 

The momentary switch, keyed switch, and JST pigtail are assembled in a triangle with the 10cm wire as one leg of the circuit and installed in the "Top". Beware of installing in the wrong order as the two switches need to be disassembled somehow to fit or assembled in situ. Attach the camera ribbon to the camera module. You may need to put a couple turns in the ribbon to make it fit nicely. Do this at your own risk as these ribbons can be fragile if pinched or bent. Plug the power switch assembly JST connector into the corresponding connector on the x1202 and slot the "Top" onto the whole assembly paying attention the positions of the power wires and camera ribbon. Tighten the four M2.5 screws on the top of the assembly and the single one in the corner on the bottom of the assembly.

Place the watch glass in the recess over the top of the camera lens and use the nylon washers and m3x6 bolts to hold it in. This piece is also fragile so be careful to not over tighten the screws.

Tip: Using some phone repair tape (x) under the glass may be a good idea but it will work fine without.

Place, in order, [the m4 fender washer, d-ring, m4 flat washer, and m4 nylock nut] onto the m4 hex cap bolts that are sticking out of the sides of the "Bottom".

Tip: Some adhesive bumpers on the bottom of the case help it not slide but are not required.

The トマト on the "Top" is an homage to Edward from Cowboy Bebop. Her computer is made out of trash and the case is a tomato box and has the label on the side. I may release a blank one in the future.