I wanted a nice case for the MiSTer FPGA, and I wanted a case to protect the MiSTer FPGA, so I tried a 3D printed case, but I did not like it very much and I had to make some modifications to it because I had newer versions of the MiSTer FPGA IO and USB board, so I decided to try to use ether a computer case or project box for my MiSTer FPGA, BTW something that I noticed was that the computer cases were often ether too small, or too big, and that project boxes were hard to find in a larger size.
Then I found a nice looking aluminum project box that was 250x205x100mm in size, made with 1.5mm thick aluminum, and I decided to try it, the box was nice and well made, however the aluminum is a bit soft, and this box was pre-painted with a "silver" paint of some kind and for better or worse the paint is pretty tough.
The next step was figuring out the placement of all the buttons and plugs I was going to install, LOL, I used Microsoft Paint to make a grid of 10MM squares that was 250mm by 100MM in size, then made drawings of the parts I was going to use with 10MM and 5MM blocks, I used the part sizes listed on the product's web page.
The next step was to draw that grid on the backside of the project box face plates, I did not want the lines to change or get erased has I worked on the face plates, so I used a metal scribe to mark the lines, I then laid out the buttons and other parts on the grid, for the USB plugs and buttons I just used the nut that holds them in place, then I used a pencil to mark were I wanted them, I tried to keep everything lined up to the grid, sometimes with the buttons and USB plugs I made extra lines at 5MM that were half of one or more of the 10MM squares to keep the holes lined up, BTW make sure to remember you are working from behind the face plate so you don't mess up your placement on the front of the face plate.
Next I used a center punch to mark the center of the holes, and I start the holes with a 2MM drill bit, you just keep using larger and larger drill bits until you get the hole size you need, for mounting stuff to the project box I finished with a 3.5MM drill, for buttons, USB, Ethernet, and video connectors I still started with a 2MM drill bit and worked up to a 3.5MM drill but then went to a step drill to finish the hole.
To make the square holes I used a nibbler, I used a metal scribe to draw the square I want using the grid to keep it lined up, and I drill a hole in the square large enough for the nibbler to fit into, then I start cutting with the nibbler, you need to go slow and let your hand have some rest now and then.
I tried to figure out how I was going to mount the MiSTer FPGA to the bottom of the project box, and made a few mistakes because I was in a hurry, I drilled a few extra holes, LOL, also I worried about breaking off one or more of the ports or connectors if I got too rough with the MiSTer FPGA when trying to cram it into the small project box, something that helped me a lot was mounting the MiSTer FPGA and power supply up off the bottom of the project box about 20MM to 30MM to allow some of the wires to go under them, I used 3MM brass standoffs to mount the MiSTer FPGA, 5v power supply and MiSTer MT32-Pi to the project box, I also used a 3D printed part to cover the back of the Raspberry Pi 3 B+, I noticed that I was sometimes bumping into the back of the Raspberry Pi when moving stuff around, and was afraid I would eventually knock a part of of the PCB board and damage the Raspberry Pi.
For the LEDs I used 1/8W 1% Resistors, and used this web page to calculate what resistors I needed:
Current Limiting Resistor Calculator for Leds
http://ledcalc.com/#calc
for the "M16F-Y ATI 16mm Momentary Yellow LED 1.8V" I used a 220 Ohm, for the "M16F-R ATI 16mm Momentary Red LED 1.8V" I used a 220 Ohm resistor, for the "M16F-G ATI 16mm Momentary Green LED 2.8V" I used a 150 Ohm resistor.
I ordered a "LANMU Micro SD to SD Card Extension Cable Adapter (18.9in/48cm)" from Amazon, it worked on my computer so I "thought" it would work on the MiSTer FPGA, but I was wrong, I thought that the cable was too long at 18 inches, so I cut the cable in half and soldered the shorter end back to the SD card socket, still works on my computer and still fails to work on my MiSTer FPGA, so I ordered the (9.8in/25cm) long one and it works, well that's strange.
Here is how I wired the buttons and LEDs.
MiSTer FPGA_bUTTONS_001.png
Here is how I wired the power.
MiSTer FPGA_Power_001.png
Here is a look inside from the top.
MNISTER_FPGA_CASE_INSIDE_007.jpg
Here is the front of the case.
MNISTER_FPGA_CASE_OUTSIDE_002.jpg
Here is the back of the case.
MNISTER_FPGA_CASE_OUTSIDE_003.jpg
A view of it powered on with the top removed, this was before I installed the SD card SD Card Extension Cable.
MNISTER_FPGA_CASE_OUTSIDE_AND_INSIDE_001.jpg
====MiSTer FPGA parts that I used:
----------eBay
MiSTer FPGA 7 Port USB HUB V2.1 w/ Bridge Board and Power Splitter Cable - it's nice and works well, but it would save space in a small case to use a small USB hub.
https://www.ebay.com/itm/MiSTer-FPGA-7- ... 4406703859
Mister FPGA SD Board XSD v2.5 128MB - you need this for cores like AO486
https://www.ebay.com/itm/Mister-FPGA-SD ... 3882448497
Mister FPGA IO Board v6.1 XL Newest Revision!
https://www.ebay.com/itm/Mister-FPGA-IO ... 4757587060
VGA Pass Through Panel Mount D-Series connector flange panel jack
https://www.ebay.com/itm/VGA-Pass-Throu ... 2995996731
Wall plate: VGA Female/Female & Stereo TRS 3.5mm Audio Gold Plated Ivory - I only used the panel mount audio connector from this.
https://www.ebay.com/itm/Wall-plate-VGA ... 2614555629
M16F-Y ATI 16mm Momentary Yellow LED 1.8V 4.3V PushButton Switch Flat Top MOD - User button and LED - kinda bright
https://www.ebay.com/itm/M16F-Y-ATI-16m ... 1589389723
M16F-R ATI 16mm Momentary Red LED 1.8V 4.3V Push Button Depth Flat Top MOD - User button and LED - kinda bright
https://www.ebay.com/itm/M16F-R-ATI-16m ... 2338931978
M16F-G ATI 16mm Momentary Green LED 2.8V 4.3V Push Button Depth Flat Top MOD - User button and LED - kinda bright
https://www.ebay.com/itm/M16F-G-ATI-16m ... 2338932019
Panel mount HDMI connector flange mount panel jack
https://www.ebay.com/itm/Panel-mount-HD ... 2948175305
USB 2.0 3.0 Female Socket Plug Panel Mount Adapter Waterproof Connector With Cap - It took about 22 days to get from China
https://www.ebay.com/itm/USB-2-0-3-0-Fe ... 2494337048
----------Amazon
10 Pairs DC Power Pigtail Cable, 12V 5A 2.1mm x 5.5 mm Male & Female Connectors - I had them for another project I was working on, connects to 5V power supply.
https://smile.amazon.com/dp/B07PS8T2KM
8Bitdo Wireless USB Adapter - works well but you need to update the firmware on a PC when you get it.
https://smile.amazon.com/dp/B0786JC6VW
Tysun Silver Aluminum Electronic Enclosure Project Box - very nice metal box, but almost too small - do not over tighten the screws or you will strip the threads.
https://smile.amazon.com/dp/B08G4ZKVL1
Real Time Clock Board V1.3 Board for Mister FPGA - needs a CR1220 battery.
https://smile.amazon.com/dp/B08Q4C5SDN
Panasonic CR1220 3 Volt Lithium Coin Battery
https://smile.amazon.com/dp/B014WXZO0G
CanaKit Raspberry Pi WiFi Wireless Adapter/Dongle - this works, but I mostly use Ethernet.
https://smile.amazon.com/dp/B00GFAN498
SanDisk 400GB Ultra microSDXC UHS-I Memory Card - I have only used a little over half of the storage on this card.
https://smile.amazon.com/dp/B08GYG5SVQ
M3 Male-Female Brass Spacer Standoff Kit - I used this on the MiSTer FPGA and MT32-Pi, I used a 3.5mm hand drill to enlarrge the holes on the MT32-Pi and Raspberry Pi.
https://smile.amazon.com/dp/B06Y5TJXY1
MEAN WELL 323282 RS-25-5 AC to DC Power Supply - works well.
https://smile.amazon.com/dp/B00DECXUD0
Noctua NF-A4x10 5V, Premium Quiet Fan, 3-Pin, 5V Version (40x10mm, Brown) - make sure to get the 5V version.
https://smile.amazon.com/dp/B00NEMGCIA
Quentacy 19mm 3/4" Latching Push Button Switch 12V DC 5A 250V AC LED Power Symbol ON-Off - works just fine on 5V.
https://smile.amazon.com/dp/B07JH9DKLQ
URBEST 10A 250V AC 3 Pcs Rocker Switch 3 Pin - the quality seems fine for this application.
https://smile.amazon.com/dp/B082Y57256
LATTECH 8 PCS 7 PIN JST XH Female Connector on Both Side - 300mm - for the user LEDs.
https://smile.amazon.com/dp/B07Q3CKJ51
LATTECH 12 PCS 5 PIN JST XH Female Connector on Both Side - 300mm - for the user push buttons.
https://smile.amazon.com/dp/B07NV59YCQ
Monoprice 105441 1.5ft USB 2.0 A Male to A Male 28/24AWG Cable (Gold Plated) - they work but the plug is a bit long for working in a small case.
https://smile.amazon.com/dp/B009GUXG92
Aux Cord for Car, CableCreation [2-Pack, 1.5ft, Nylon Braided]
https://smile.amazon.com/dp/B01K3WX6JG
Duttek USB Header to Micro USB Dupont Cable, 90 Degree Right Angle Micro USB Male to 5 Pin - I used this to connect power to the mt32-pi.
https://smile.amazon.com/dp/B072Q1MBSG
Monoprice 1.5ft Ultra Slim SVGA Super VGA 30/32AWG M/M - just about the only low profile VGA cable I could find.
https://smile.amazon.com/dp/B004C4XIOK
Ltvystore 1260PCS 63 Values 1 ohm - 10M ohm 1/8W Metal Film Resistors Assortment Kit - resistors for the user LEDs
https://smile.amazon.com/dp/B06XSHCMVV
LoveRPi Raspberry Pi 3 B+ Computer with Heatsinks - this is for the MiSTer MT32-Pi - I used an old SD card for the MT32-Pi software
https://smile.amazon.com/gp/product/B01CMC50S0
LANMU Micro SD to SD Card Extension Cable Adapter Flexible Extender (9.8in/25cm) - this one worked when the (18.9in/48cm) did not.
https://smile.amazon.com/dp/B07WLKLTTY
----------Other
MiSTer MT32-Pi - price was good and the shipping was quick
https://www.legacypixels.com/mister/
I used a short, thin, and cheap looking HDMI cable that I had got with something else years ago and never used, the cable was about 40cm long.
----------Tools and Supplies
Pro'sKit 900-215 Nibbler - cheap but usable - I used this to make square holes, you need strong hands for this, go slow and take breaks.
https://smile.amazon.com/gp/product/B000BN60XW
Step Drill Bit Set - I used a very cheap set to make round holes for the buttons, BTW the aluminum project box I used has very soft aluminum and the cheap step drills have a bad habit of pushing the metal out of the way and not drilling, basically when the aluminum gets hot and soft the step drill starts pushing metal instead of drilling metal.
Metric drill bit set - I used a very cheap set, and mostly used 2MM to 3.5MM drills, the 2MM drills were used to start the holes for buttons and mounting things, and I used the 3.5mm drill for the last drill size for mounting things like the power supply and the MiSTer FPGA.
I also used a cheap center punch and metal scribe to mark were to drill the holes.
Woodstock D4089 Machinist Square Set, 4-Piece - I have had them for years - used to help mark lines on the metal box for hole placement.
https://smile.amazon.com/gp/product/B005W16YSO
I used various M3 screws and M3 lock-nuts, I used M3 screws from the "M3 Male-Female Brass Spacer Standoff Kit" for mounting the MiSTer FPGA, MT32-Pi, and the 5V power supply, I used M3 16MM screws and lock-nuts for the HDMI, VGA, Ethernet, and the SD card Extender Panel Mount.
I used zip ties.
VELCRO Brand ONE WRAP Thin Ties - I love these things - better than zip ties when you have to make changes.
https://smile.amazon.com/VELCRO-Brand-R ... B000F5K82A
----------3D printed parts
Raspberry Pi 3 Slim Case with Heatsink Cutout - I only used the bottom, and I used some M3 standoffs to make a gap between the Raspberry Pi and case, used for protection.
https://www.thingiverse.com/thing:1415895
SD card Extender Panel Mount - I had to sand off a bit of plastic from each side of the SD card Extender to get it to fit inside of this 3D printed part.
https://www.thingiverse.com/thing:3854077
MiSTer FPGA Real Time Clock & IO Board Supports
https://www.thingiverse.com/thing:4337299