KK12 Kalahari Khabu-compatible front panel

Motivation

I broke the front panel of my KK12 Kalahari Khabu Biltong Boss box. I designed this compatible front panel, housing for the PCB, and bezel. The design replaces the self-tapping screws KK12 uses w/ M3x10-ish machine screws and heat set inserts.

Printing

Slicer settings

I used PLA, but if you're concerned about temps being too high, PETG should also work. The "ears" of the BarBody requires supports

Color settings

Every component of "BarBody" prefixed with "Main" should be the same (preferably dark) color , while components prefixed with "Text" should be a contrasting (lighter) color. 

Additional BOM:

• 3 x M4 heat set inserts

  • for the bottom of the bezel

• 10 x M3 heat set inserts

  • for everywhere else

• 10 x M3-10 machine screws

  • slightly longer and slightly shorted are acceptable too

• 3 x M4 pan head Phillips machine screws

  • The original front plate uses these screws, just harvest those when taking the original front plate off

NOTE:

The tolerances are slightly off and I didn't want to reprint to fix them. I made everything fit by applying force (hammer) to various slightly-off features. The Fusion360 files are provided if someone else wants to adjust them parametrically.

I couldn't get my screwdriver into the tight spaces behind the bezel, so the bezel and the light-up bar are held by the 2 middle screws. 

In the Fusion360 file, the Lid is facing the wrong way; the notch should be on the top side. However the Lid is symmetric, so I didn't bother rotating it. It will print just fine