2 min read, 400 words

Building an enclosure for my EtherMesh-1W

I finally had the alignment of free time, parts, motivation, and remembering my project list, so today my EtherMesh-1W moved into its permanent home. I went with parts on hand, because I’m at that point in hobbies apparently, so the enclosure is massive, which worked in my favor when the ipex pigtail length and board placement on the backboard (which was its own thing) led me to flipping it over and maintaining bend radiuses that way. Crossing the streams is fine when its orthogonal, right?

Anyway, despite taking my time and gathering all the parts and looking at them real hard and thinking it through, I still managed to put BOTH penetrations in places that made it both awkward to get the back plate in (expected) and awkward to screw the backplate down (unexpected, but not really a big deal). I even measured the thickness of the wall to ensure both my bulkhead fittings would have enough threading… Oh well.

I went with some AliExpress smurf tube that claimed outdoor/UV safe and a matching waterproof fitting for the ethernet from the house to the enclosure, didn’t want to deal with exterior rated ethernet and all I had on hand was CMR. I have my doubts on the UV resistance long term, but it was cheap and I’ve been surprised before.

Disassembled ethernet conduit assembly, showing the plastic nut, body, glad and conduit, with a flexible bushing on a green self healing cutting mat.
Close up of the conduit gland assembly
Gland installed in the enclosure without conduit, showing the ethermesh in the background.
Gland mounted in the enclosure with no conduit.

I was unable to deal with the complete misalignment of my backplane’s screw grid and the EtherMesh’s screw holes, but that’s a me problem and I solved it with the magnificent tolerances of nylon screws and standoffs. Nothing moves, not even the PoE magnetics daughter board, which I affixed with some 3M VHB double-sided tape… If it can handle my drone flying it can handle a pole mounted life.

Plastic enclosure containing a MeshSmith EtherMesh-1W, connected via an ipex to a N-Type bulkhead connector with an Alfa Antenna exiting the top. Blue Ethernet enters through a waterproof gland at the bottom, covered in Nylon conduit on the exterior.

Obligatory "Phew, blinkin lights" check at the top of the ladder

Well, its up on the roof, awaiting me figuring out where I want to more permanently affix it. Until next time!


This is a post in the EtherMesh-1W series.
Other posts in this series:


Ethermesh-1W hardware and software bench testing