Revamped Pi Rack Chassis

thingiverse

All credit to the original creator of this design goes to me. I've made several modifications that I'll outline briefly. The cable management arm on the sled carrier required supports, which I deemed unnecessary, so I removed it. The carrier itself is riddled with artifacts. I corrected some of them, and now it prints fairly well, but there are still numerous small gaps and oddities in the final print that don't affect its functionality. There are two versions of the Pi sled available. One features a square cutout in the center, designed for plain Pis with standoffs moved to match current Rev Pis' dimensions. I also increased its width by about a millimeter so it stays within the carrier's tracks. The other version, Rev B, is meant for use with Pis that have a PoE hat and allows you to insert a screw from behind to utilize the standoffs included with the PoE hat. Note that you'll need to remove the fan from the PoE hat. I highly recommend adding heatsinks to the processors (see picture). Additionally, I've redesigned the rack ears. They're now slightly wider, adjusted to fit standard EIA rack spacing, and each ear is keyed to fit into the carrier's indents for better support (the two ears are different; pay close attention while assembling). With the introduction of the PoE hat, heat dissipation became a significant issue. Five 80mm fans will fit perfectly across the rear of the chassis (I used Noctua NF-A8 fans), requiring two large fan brackets and eight intermediate fan brackets. Note that you'll need to trim the intermediate brackets with a hot knife as each one needs to be slightly different. Using this method proved easier than printing eight separate versions.