Revision 2: a nice(r) enclosure (1)
An important way of finding out if your product is working well, is to actually use it. In order to use the internet radio, the best way would of course be to put it in the kitchen or living room, so that it can be turned on and used at any time.
I used an enclosure that I made before, for an FM radio experiment that didn’t work out very well. The front panel had to be modified to accommodate the screen and the four buttons, in addition to the volume-and-on-off potentiometer.
In addition to the enclosure, that project also donated the TBA820 2W amplifier to drive the bigger speaker. Effectively, the LM386 was bypassed in this revision, and the output of the DAC was redirected to the TBA820’s volume control potentiometer.
Revision 2: a nice(r) enclosure (2)
A second revision of the case yielded an even better result. This time the case was custom made for this project, based on the previous one.
The outer case is made from rubberwood: planks of ~12mm thick and 12cm width. There are two boards of 22.5cm x 12cm, for the case top and bottom. There are two boards of 14cm x 12cm, one for each side. The board edges are cut at a 45° angle. The diagram below shows the measurements for the small and large boards. (You need 2 of each.)
Grooves are routed to hold the front and back panels in place: for the front, there are two grooves of 3mm width, spaced 3mm apart. For the back, there is one 3mm groove. The front and back grooves are routed ~1cm from the edge.
The top and side panels are permanently glued to each other; the bottom is mounted using screws, so that it can be easily removed for maintenance.
As for the previous case, the front panel is actually made of two panels mounted against each other. There is a 6mm thick panel that holds the different components in place: the I/O board with LCD and buttons, the on/off and volume potentiometer, and the speaker. The router was used to make the cutouts and ridges:
The following picture shows how everything fits together. Starting from the bottom, the front panel and the mounting panel sit next to each other. The main PCB is mounted to the back panel:
The end result: