Waterproof forumslader housing

thingiverse

This is a watertight enclosure for the [Forumslader](http://www.forumslader.de/automatiklader/), a device that charges your USB device with the hub dynamo of your bike in an extremely efficient manner. The example is designed to fit the 2.9Ah version with three LiMn 18650 batteries. It is fully customizable, so you can adapt it to other versions. I added a dovetail joint for future bike mounts. It's based on this enclosure: https://www.thingiverse.com/thing:3147316 and optimized for the battery compartment from Enif: https://www.thingiverse.com/thing:456900 There are holes with compartments for: * The USB plug * A mini Tamiya plug (male) To save space, it needs to be shortened by a cutter. * A BEC plug (male) To save space, it needs to be shortened by a cutter. * The pressure compensating element See also here: https://www.bopla.de/gehaeusetechnik/product/kabelverschraubungen-allgemeines-zubehoer/kabelverschraubungen/dae-m12-7035.html and here: https://www.conrad.de/de/druckausgleichselement-hellgrau-bopla-dae-m12-5-st-520324.html and here: https://www.ebay.de/itm/Druckausgleichselement-IP68-incl-GM-Stopfen-Verschraubung-Druckausgleich/302662017677?hash=item46780fe28d:m:mL82eGRW8tCtpUw0RgViRLw * The button * The LED To be watertight, there needs to be a gasket in the form of a rubber ring, which can be found in office supply stores. The rubber ring should have a 1.5mm thickness and 240mm total length approximately. You need four water-resistant screws 3.0mm x 16mm. The compartments for the plugs, the LED, and the button need to be filled with hot glue. There are four OpenSCAD files: * housing.scad is the module that contains the logic * housing_forumslader.scad is the file with the parameters * flexbatter18650x3.scad is the battery compartment (from Enif: https://www.thingiverse.com/thing:456900) * dovetail.scad is the module for the dovetail mount. Included are also the ready-to-print .stl files for the bottom part, the top part, and the battery compartment. Printing information: Open the housing_forumslader.scad in OpenSCAD. **Important**: The preview doesn't show everything correct due to the complex structure. Press F6 in OpenSCAD to render it. The variable names should be rather self-explanatory. The inner size does not include the screw sockets, so the available volume is a bit smaller. The dimensions of the rubber gasket are printed in the console output of OpenSCAD. The tolerances and gaps should be fine for a calibrated printer. You can switch on or off the big surface might make the bed adhesion at the corners problematic. I was using ASA as material (ASA is UV-proof and sturdier than PLA) and Cura as slicer, and these settings (beside my standard profile): * wall line count: 8 * top/bottom thickness: 0.8 * bottom thickness: 0.8 * infill density: 100% * generate support: yes * support overhang angle: 70 * build plate adhesion type: brim * support join distance: 10 * support overhang angle: 55 Additional information: * ASA is sturdier than PLA and UV-Proof for outdoor use, but more difficult to print. * Don't tighten the screws too much; the groove between top and bottom part should be constant along the sides. * No guarantee on the watertight performance! The area around the groove for the rubber should be perfect. The compartments for the plugs, the LED, and the button need to be filled with hot glue. * Use clothes pegs for fiddling in the rubber ring * Disadvantage: Quite a waste of space * Advantage: Batteries can be replaced or taken off during flight, watertight * Weight of the housing alone: approx. 90 g