Plywood+Enclosure+Assembly

Plywood Enclosure Assembly Top Panel, Post, and Lampshade Velcro Component Placement and Connections Software and Troubleshooting

==Plywood Enclosure Assembly==

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> > > Also, for the satellite:
 * Twenty-four plywood pieces are needed for constructing the boxlab enclosure.

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 * Sand and paint the pieces. A wood stain paint was used for the horizontal and vertical bars. All bars and panels were then painted over with polycrylic. Pay attention to warning notes on the paint cans.
 * The horizontal bars should be fit together to form the top and bottom rectangular frames. Two of the smaller horizontal bars should slide and lock into the slots of two of the larger bars. Do this twice to make two frames. Due to the tolerances the press fit joints might be difficult to fit each other. In that case, a rubber-headed hammer might be useful.
 * After constructing the frames, the vertical bars should be attached to the frames. Begin with the lower frame. Slide each end of the lower frame through the hole of the vertical bar.
 * With 4 vertical bars attached to the bottom frame, place the top frame into the slots on the top of the vertical bars and the structural frame is complete.
 * Simplified diagrams of the construction process are shown below.
 * After creating the structure the panels could be attached but before that a thin noise and vibration absorbent material should be glued to the panels. We used a thin floor-to-floor carpet for covering the panels. This material should be cut in the shape of each panel, but leave a half-inch of space between the panel and carpet. Be sure to also cut out holes corresponding to the holes on some of the panels as well.
 * When aligning the panels, notice that there is a side panel with a window for ventilation. Note that the window is slightly off center. When placing the panel in, the distance between the top frame and the window should be greater than the distance between the bottom frame and the window. Also, be sure to align this side window with the window on the bottom panel, as shown in the picture above.
 * Now assemble the shelves for the HDD, modem, A/V receiver, wireless sensor receiver and remote power management tools (ex. Controlled power strip, cell remote controller, and international power controller; room unit only contains a controlled power strip).  The upper shelf is left unglued to enable easier access to items on the lower shelf.
 * From the sound-insulating convoluted egg crate foam, cut out the pieces in the template picture below. In the picture, the side facing up is the convoluted side. The square hole on the smallest cutout is meant for attaching the 80mm square computer case fan later; the sides of the square should be less than 80mm so that the fan can fit snugly.
 * In between two walls two pieces of foam creates the two channels for cold and hot air. The cold air channel houses a fan that is powered by the computer’s fan cable. The external fan is a stock part that is widely available. It is simply a 80mm case fan and should come with the necessary cables and sockets.
 * To secure panels onto the frame structure use 1” steel wood screws. Mark and drill indentations 10mm square from the corners so that the head of the screws will not jut out from the plane of the panels.
 * Once the indentations are completed, completely assemble the panels.
 * Now drill in the screws to create a place for them on the frame structure so that you do not have to do this later with all the components inside.
 * To prevent scratching up the floors of participants’ homes use some felt sliding pads for the feet of the enclosure.