Imported from GitHub: VanceVagell/kv4p-ht · commit 80bbcef · license GPL-3.0

Description

Open source handheld ham radio project KV4P-HT

README

Filenames may vary—use the most recent release assets for printing.

---

Case Options

1) Thin Case (full enclosure)

• Purpose: daily protection with a slim profile that still allows good grip and access to controls.
• Lids:
  • Solid Lid (no magnets) — clean look, maximum rigidity.
  • Magnet Lid — same geometry with Ø12.5 mm × 1.5 mm pockets for disc magnets.
• Fasteners: 6× M3 screws into M3 heat-set inserts (install depth 5 mm).
• Access & cooling: body shape preserves ventilation paths and control access (depends on radio model cutouts).

2) Cradle Case (radio + phone)

• Purpose: mount the HT and keep your phone docked for digital modes, logging, APRS maps, etc.
• Radio interface: same magnet pocket spec (Ø12.5 mm, 1.5 mm depth) to attach to a radio-mounted backplate.
• Phone shelf: flat cradle surface with front lip; add thin foam or rubber tape for grip and to protect the phone.
• Cable-friendly: open edges accommodate common audio/PTT or data cables (model-dependent).

---

Bill of Materials (per case)

Item	Spec	Qty	Notes
Heat-set inserts	M3, 5 mm install depth (standard brass)	6	Thin Case only
Screws	M3×6–8 pan head	6	Match length to your printer’s fit
Magnets	Disc Ø12.5 mm × 1–1.5 mm	up to pockets	Use N35–N52 neodymium
Adhesive for magnets	CA (super glue) or 5-min epoxy	—	CA is quick, epoxy is stronger
Foam/rubber tape (optional)	1–2 mm thick	as needed	Phone shelf grip / anti-rattle

The magnet pockets are 1.5 mm deep. If your magnets are 1.0 mm thick, add a thin CA layer or adhesive pad behind them to sit flush.

---

Printing Guidelines

• Material: PETG recommended (tough and heat-resistant). ABS/ASA also good for outdoor use. PLA+ is acceptable indoors.
• Layer height: 0.20 mm (0.16–0.24 mm works).
• Perimeters: 3–4 walls for strength around inserts and magnets.
• Infill: 20–30% gyroid or grid (40% for the phone shelf if you prefer extra rigidity).
• Top/Bottom: 4–6 layers.
• Supports: Only if your printer struggles with the phone lip or specific overhangs (most parts are support-light).
• Orientation:
  • Thin Case body/lid: print flat on the largest face.
  • Cradle body: print flat on the backplate side; phone shelf flat.

---

Assembly — Thin Case

1. Test fit the printed parts. Clean any brim/elephant’s foot so edges meet flush.
2. Install heat-set inserts (6× M3):
   • Set a soldering iron to a temperature appropriate for your plastic (typ. 200–240 °C for PETG; lower for PLA).
   • Press inserts straight down to 5 mm depth. Keep square—do not over-melt.
3. (Optional) Install magnets in the magnet lid:
   • Dry-fit magnets into the Ø12.5 mm × 1.5 mm pockets.
   • Mark polarity before gluing so this lid matches your other magnet surfaces.
   • Bond with a small drop of CA; press flush. Let cure.
4. Mount the radio in the case body; verify clearance for knobs, PTT, jacks, and battery latch.
5. Fasten the lid with M3×6–8 screws. Tighten snugly—no need to over-torque.

---

Assembly — Cradle Case

1. Dry fit the cradle body and phone shelf; ensure your phone sits securely.
2. Add grip: apply 1–2 mm foam/rubber tape to the shelf to protect the phone and prevent sliding.
3. Install magnets (if used) in Ø12.5 mm × 1.5 mm pockets. Keep polarity consistent with your radio backplate.
4. Mate the cradle to the magnetized radio backplate. Check cable clearance for your setup.

---

Magnet Polarity Tips

• Choose a standard: e.g., “logo side = North.” Mark one face of all magnets before installation.
• Always test polarity against the mating part before gluing. Magnets are unforgiving once set.

---

Compatibility & Remixes

• These enclosures are designed around the KV4P open-source HT project version 2.0 geometry.
• PRs with alternate cutouts, belt-clip adapters, lanyard loops, or tripod-mount blocks are welcome.

---

Case Types

• Phone Cradle Case - This design allows you to cradle your phone and gives you a pocket where you can place items such as your USB cable. Tested with a Google Pixel 5a phone.
• Thin Case - This is a case to fully enclose your radio while keeping the footprint as small as possible. Has built-in PTT switch that doesn't protrude.

---

Hardware Needed

• 1.5 mm thick x 12mm diameter neodymium magnetic discs. This is needed if you want to use a magnet mount on the back of your phone. Example Part on Amazon: https://amzn.to/4mEPLiD
• M3 8mm long bolts with Button Heads - Example Part on Amazon https://amzn.to/4oXybrI
• M3x5x4.2 Heat inserts - Example Part On Amazon: https://amzn.to/41qj5kE