Nema23 SERVO57C servo protective case with connector

I didn't like the case provided by Makerbase for the Servo57c, it still leaves a lot of open holes for chips to come in and might damage your controller. I wanted it to look more like a professional servo ;). So I started drawing, this is my result for now. I am waiting for the connectors to arrive. 

I also included the Fusion360 project. For those who want to fit in there own connector, just edit the “ConnectorHole” sketch. Internal there is ~ 26x26mm space, outside there is ~ 32x32mm of space

Remixing is allowed, but please remember to refer back to this page.

NOTE: 
- Some Nema23 Motors need drilling and tapping, but for the most it should just fit. This can be done the easiest by removing the back plate.
- The JST connector needs to be removed from the PCB!

Needed material:

• designed for this connector, I choose the 10 pin (explained below)
  https://www.aliexpress.com/item/4000106371464.html
• the MKS Servo57c controller
  https://www.aliexpress.com/item/1005004776501066.html
• 6x 2x15 flat head screws
  4x 2x20 flat head screws
  I bought this kit:
  https://www.aliexpress.com/item/32804897722.html 
• a Nema23 motor
• 4x M3x10 flat head bolts.
• 4x M3x4x4.2 Hot melt insert nuts. I bought this kit:
  https://www.aliexpress.com/item/1005003174906572.html
• A good shielded and flexible cable with at least 6 wires.

Print instructions:

• I would recommend ASA to print the parts. But ABS / PETG will probably work as well
• The knob needs to be printed 3 times. These are quite small and challenging to print, adding a brim of 5mm might make it easier.
• The “BackAndDisplayCase” and “ButtonText” can be printed in multi color. If you can not print multiple colors just print it without the text and add a support blocker over there. 
• The other parts should be printed with support.

Mounting instructions:

Preparations:

1. Print the parts
2. Test if the knobs can move freely in there holes.
3. Remove the JST connector from the PCB. 
   >> I cut the leads on the back of the connector and removed the pins from the holes using solder wick and a little pushing with my soldering iron.
4. (optional) Drill and tap m3 holes in the back plate of your stepper motor. 
   >> In my case this was necessary because I was not able to insert another M3 screw in the existing holes. With “StepperOnline.com” Nema23 motors the drilling and tapping is not needed.
5. Insert the hot melt nuts with a soldering iron.
   >> I always set it to ~ 240 degree Celsius and have a little patience ;)
6. Solder ~10cm wires to the connector 
7. Mount the connector to the "MotorAndConnectorCase" using the m3x10 flat head bolts
8. Glue the magnet to the axis of the stepper. 
   >> I used a printed adapter for this to center the magnet. Because every motor is different you have to design this adapter yourself.

Installation:

1. Lead the motor wires through the hole in the connector case. 
2. Screw the "MotorAndConnectorCase" with the PCB on the back of the stepper motor. 
   >> I used the bolts that came with the Servo57C.
3. Solder the wires from the connector to the PCB pads where the JST connector was.
   >> See the second Photo
4. Connect the motor wires.
5. Test everything and do the calibration.
6. Insert the knobs and screw the "BackAndDisplayCase" to the “MotorAndConnectorCase"