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Router-Cut Project Enclosure
Woody

Imeundwa na

Woody

14. Agosti 2026NO
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Router-Cut Project Enclosure

A plywood case for a finished electronics project, cut with a trim router against a template rather than freehand. A template matters the moment you build a second one: make the template accurate once, and every case that follows it is identical. The same method cuts the display window, the card slot and the cable opening. Sized here around an Arduino-and-shield stack, so it suits the data-logging thermometer and the GPS position logger directly.
Kati
4 hours

Maagizo

1

Measure the stack and mark the template

Measure the assembled board stack including the cables, then add clearance on every face.

  1. An Uno with one shield is roughly 70 × 55 mm in plan and about 35 mm tall once stacked.
  2. Add 5 mm clearance all round, and more at the USB end where a plug sits proud.
  3. Mark the window on quarter-inch plywood with the speed square and pencil.
The template is the only part that has to be accurate. The case merely copies it — so any error you leave here is reproduced in every case you ever cut from it.

Vifaa kwa hatua hii:

Baltic Birch Plywood (1/4in)Baltic Birch Plywood (1/4in)1 karatasi

Zana zinazohitajika:

Hultafors MRS 18 Speed Square — MetricHultafors MRS 18 Speed Square — Metric
Hultafors Carpenter's Pencil HBHultafors Carpenter's Pencil HB
Ryobi RTM8M Tape Measure 8 mRyobi RTM8M Tape Measure 8 m
2

Cut the template opening and finish it to the line

Cut just inside the line, then work back to it with a sanding block.

  1. Rough the opening out with the jigsaw, staying about 1 mm shy of the line.
  2. Sand to the line, checking with the speed square that the corners stay square.
  3. Test-fit the board stack through the opening before going any further.
Finish the template completely before touching the workpiece. Correcting a template costs one offcut; correcting a routed case costs the case.

Vifaa kwa hatua hii:

SandpaperSandpaper1 karatasi

Zana zinazohitajika:

Ryobi ONE+ RJS18-0 Cordless JigsawRyobi ONE+ RJS18-0 Cordless Jigsaw
3

Cut the six case panels

Cut the panels from three-quarter-inch plywood: two sides, two ends, a base and a removable face.

  1. Set the mitre saw to a true 90° and confirm it against the speed square, not the scale printed on the saw.
  2. Cut all like parts in one setup without moving the fence, so opposite faces come out identical.
  3. Label each panel on its inside face as it comes off the saw.
Cutting matching parts in one setup is what makes a box square. Re-setting the fence between two panels that should match is the usual reason a case will not close.

Vifaa kwa hatua hii:

Baltic Birch Plywood (3/4 inch, 24x30)Baltic Birch Plywood (3/4 inch, 24x30)1 karatasi

Zana zinazohitajika:

Ryobi ONE+ R18MS216-0 Cordless Mitre Saw 216 mmRyobi ONE+ R18MS216-0 Cordless Mitre Saw 216 mm
Ryobi ONE+ RB1850X 18V Lithium+ Battery 5.0 AhRyobi ONE+ RB1850X 18V Lithium+ Battery 5.0 Ah
4

Rout the opening against the template

Clamp the template to the face panel and follow it with a bearing-guided flush-trim bit.

  1. Clamp both template and workpiece to the bench — never hold either by hand.
  2. Set the bit so the bearing runs on the template edge and the cutter clears the workpiece.
  3. Take the depth in two or three passes, not one.
  4. Feed the router against the bit's rotation — left to right on the near edge of the work.
Feeding the same way the bit spins lets the tool climb and run along the work, dragging itself out of your control. That direction is the single most important habit with a router. Wear eye protection: a trim router throws chips continuously.

Zana zinazohitajika:

Ryobi ONE+ HP RTR18C-0 Cordless Trim RouterRyobi ONE+ HP RTR18C-0 Cordless Trim Router
Ryobi RAKRBS5 Router Bit Set 5 PiecesRyobi RAKRBS5 Router Bit Set 5 Pieces
5

Glue and screw the carcass

Assemble five panels into a box and leave the face panel removable so the electronics can come out.

  1. Glue and clamp the base, sides and ends. Check the diagonals: equal diagonals mean a square box.
  2. Drill a clearance hole first — plywood edge grain splits readily and takes a screw poorly.
  3. Drive the screws once the glue has grabbed.
  4. Leave the face panel dry-fitted, held by four screws only.
The glue carries the load; the screws hold the parts still while it cures. A joint that relies on screws alone into plywood edge grain will loosen.

Vifaa kwa hatua hii:

PVA Wood GluePVA Wood Glue1 chupa
#8 x 1" Wood Screw#8 x 1" Wood Screw16 vipande

Zana zinazohitajika:

Ryobi ONE+ HP RDD18C1-0 Cordless Drill DriverRyobi ONE+ HP RDD18C1-0 Cordless Drill Driver
6

Sand, then fit the electronics before any finish

Sand the outside smooth and break every edge so nothing is sharp to the hand.

  1. Work up through the grits, finishing around 180.
  2. Ease the arrises with a few strokes by hand.
  3. Fit the board stack and check every opening lines up.
Test-fit before finishing, while adjustment is still a minute with a sanding block. Once oil or lacquer is on, widening an opening means refinishing the panel.

Vifaa kwa hatua hii:

SandpaperSandpaper1 karatasi

Zana zinazohitajika:

Ryobi ONE+ R18ROSN-0 Cordless Random Orbit SanderRyobi ONE+ R18ROSN-0 Cordless Random Orbit Sander

Vifaa

5

Zana Zinazohitajika

10

Blueprint zinazohusiana

Blueprint hizi zinashiriki maarifa — mbinu, vifaa au kanuni

Data-Logging Thermometer

Data-Logging Thermometer

na EdFI

Vidhibiti vidogo

2
0
0
0
0
0
GPS Position Logger

GPS Position Logger

na EdFI

Vidhibiti vidogo

3
0
0
0
0
0

CC0 Umma Wote

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