G90 Radio Desk Stand with Cooling and Power Distribution

Handles for an Xiegu G90 radio with the option to add a 120mm fan, power distribution box & 5A USB charger.  You can use just the handles by themselves, if desired, as a desk stand.

Caveats 

Please note that these .STL files worked for me, using my printer and fitting my radio.  I cannot guarantee fitment on someone else's radio, printing with a different machine.

Parts get assembled with M3 hardware.  I used cap head screws and nuts.  M3 screws worked fine in making attachments to my radio.  Verify fitment with your radio to avoid potential damage.

Most of the assembly can be infered from the attached pictures. When making screw attachments to the radio, please be cautious regarding threaded depth.  I recommend choosing screw lengths that will not penetrate into the radio any deeper than the original screws holding the handles.

With proper orientation, supports should not be needed or desired for most components.  The exception is the power distribution box which will benefit from supports for the rectangular openings on either side.

*Please note that the part named  “G90-Desk-Stand-Screen”  is intended for use as a fan guard.  It shows as solid.  I printed that item with a large honeycomb infill with zero (0) top and bottom layers.   Without top & bottom layers, only the infill and perimeters get printed. Use a high perimeter count (i.e. 10mm worth)  for enough structure.

The power distribution box is a modified version of my “Anderson PowerPole Modular Flat Distribution Box” model found here:  https://www.printables.com/model/816564-anderson-powerpole-modular-flat-distribution-box

See the discussion of that module for assembly information regarding the modules for powerpole connectors and fuses.

Wiring the distribution box is up to personal preference. There is a hole in the bottom corner for the fan wire.  A hole in the back side is there for the power running to the mini-Tamiya connector.  There are also rectangular openings for the fan switch and access to the USB A connector on the  USB charger board.

I used servo tape (double sided tape similar to rubber cement) to secure the USB charger board in it's recess.  I recommend use of crimped ferrules with the input wiring.

I used silicone insulated, fine stranded wire for flexibility.  I chose to daisy-chain the powerpole connectors, then solder the loose ends rather than use some form of buss. See the picture for details.

My build included items like or similar to the following:

Assorted M3 hardware, cap head screws and nuts.

DC Switch fitting 19mmx12mm opening - https://www.amazon.com/dp/B087PYW9BS

USB 5A Charger - https://www.amazon.com/dp/B07X5H4M42

120mm Fan - https://www.amazon.com/dp/B002YFP8BK

mini-Tamiya connector - https://www.amazon.com/dp/B08GJMSWQZ

Anderson PowerPole 45A connectors - https://www.amazon.com/gp/product/B00GPRIC8Y

6.3mm Female Spade connectors - https://www.amazon.com/gp/product/B07H889Q7W

Automotive Fuses - https://www.amazon.com/gp/product/B0042XORMI

Fusion 360 and .STEP files have been included.  The fusion 360 source has not been tidied up & is not intended as an example of best practices.