Flat Starlink case designed to be cut with a CNC. The total dimensions of the finished case are 554.35mm x 344.8mm x 30mm+height of whatever plastic you use for the lid
Instructions:
- CNC case. I used a 560mm x 350mm x 30mm piece of PE-UHMW plastic that cost around €80. I've attached the Fusion360 file which I exported to my CNC software. I suggest making separate passes with constraining areas set as: Inside for initial cut, Inside for finishing cut (optional), the outside edge of the gasket groove, the outside edge of the case (for screw holes), and finally unbounded to cut the case out of the material.
- Laser cut/CNC the top out acrylic or lexan
- Tap screw holes
- Cut your rectangular Starlink to 25mm deep. Place your Starlink dish face down. Now take a marker and place it on something like a roll of tape or scrap wood so that it's exactly 25mm off the surface. Use this to trace a line all the way around the Starlink dish. Cut. As long as you don't cut down (or really far in to the case, like 6cm) there is no danger of hitting anything. There are youtube videos showing the internals, and at 25mm the only thing possible to hit are cables that aren't that close to the edge.
- Pry case open (with a screwdriver if necessary). Pry backing plastic off of the back piece. Break clips. Remove cables.
- Cut a hole in the side of the CNC'd case to allow the grey cable to pass through
- Clean.
- Push grey cable through hole, zip-tie & attach to case with cable straps (I used small plastic clips with 3M tape on the back)
- Seal cable entry with Gorilla clear grip or similar
- Put cut Starlink dish into CNC'd case
- Put 4mm gasket cord in the groove
- Put lid in place, screw down
- Mount as you see fit. I left all the screw holes at 25mm deep in the model, but drilled a few of them through all the way to attach L brackets to.
The Fusion360 file is fully editable via user parameters. So if you want a different number of screw holes, case depth, wall width, etc it's all customizable by just changing some numbers
You could also 3D print this, but you'd need a large printer or would need to cut it into parts. Most materials aren't 100% waterproof either.
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