I have finished the changes to the XU4 Split Airflow Vertical Case. It has the following improvements:
Twin enclosed upper and lower ducts with re-positioned fanThe updated design file XU4_Split_AirFlow_Vertical_Case_RC1.scad is located in the first post.
EMMC thermally isolated with access hole
Fan cable conduit
UART placement on either side (default above Ethernet port now)
Remember to update the Library as well.
Stereo Lithography File of complete build XU4_Split_AirFlow_Vertical_Case_RC1.stl
There is a significant improvement in airflow through the case from the prototype. Both the top and bottom ducts are working great and you can feel the airflow much strong than before. A couple quick sysbench tests showed lower temperatures as well so it looks very promising. There seems to be a reduction of noise, but that's subjective for now.
I was able to hold 1mm or less tolerance in the upper duct and the lower duct mates with the bottom of the PCB. Theres a small space at the boot switch.
Build Notes to make it easier to assemble.
2) self tapping screws for UART strap
4) M3 Screws 44-48mm long with nuts
For hole cleaning: Iso_pin_holes are 4.5mm or 11/64", All others are 3mm. It is important that the deck were the pins sit are clean and flat.
While squeezing the fan iso pins at the indentation on the cone. carefully feed the fan iso pin while gently pulling from the other side.
Insert the fan into the top first. The duct is not as wide as the fan so you have to bend the fan iso pins down to the fan and then carefully slip it into position.
Notice the UART and battery are in place. By coiling the UART cable now it will be easier to connect and be more manageable. Also notice the position of the fan cable. Locate the fan in the same orientation as the picture so it is aligned with the cable conduit.
After inserting the fan in the bottom, route the cable as shown. The small portion of the shrink wrap seals the pass through hole, make sure you don't pinch the cable when you finish assembling. Afterwards lay the case on its bottom.
Carefully work the XU4 PCB into the case maneuvering the heat sink and aligning the top ductwork. Connect the fan, UART and battery cable. Insert the screws, check the alignment of everything and hand tighten.It looks like Ameridroid is going to make a kit available with this case. Are there any other changes, improvements or comments from the community?