Hardware Assembly

Hardware Assembly

Part of Hardware. Physical build for the bill of materials enclosure. Software setup is on Software Setup.

Video walkthrough

Watch on YouTube — Assembly walkthrough

Choose a build path before you print and close the case:

Option	Best for	Audio	Print profile
A - Without USB speaker	Compact build; quieter desk	No onboard speaker. Use the Web Portal Bluetooth Speaker card later for ATC / chime, or skip audio.	MakerWorld - no speaker
B - With USB speaker	Built-in ATC and hourly chime	Plug a compact USB audio speaker into the Pi before closing the enclosure.	MakerWorld - with speaker

Both options share the same Pi + Waveshare display stack. Print the matching enclosure profile before you close the case.

---

Shared: prepare the Pi and display

Do this for either option. Work with power disconnected.

1. Flash the OS first

Flash Raspberry Pi OS (64-bit) with desktop, then confirm you can reach the Pi (SSH or desktop) before you bury the board in the enclosure. Full steps: Software Setup.

2. Optional heatsink + fan

Recommended for 24/7 Pi 4 use.

1. Bore out the heatsink screw holes with a 3 mm drill bit so they clear M2.5 screws.

   

2. Mount the Waveshare Pi 4 fan heatsink with the 2× M2.5×10mm button-head screws.

   

3. Connect the fan power lead per the heatsink instructions (GPIO / fan header as supplied). After software install, install-pi.sh enables the kernel gpio-fan overlay (GPIO 14, fan on at 60°C) for the enclosure cooling fan.

   

3. Mount the Waveshare display to the Pi

1. Power off and unplug USB-C power.

2. Secure the display to the Pi with the standoffs and screws included with the Waveshare kit.

   

3. Connect the DSI ribbon between the round display board and the Pi’s DSI port (on Pi 4: connector above the microSD slot).

   ·

4. Leave any I2C address DIP switch in the factory position.

   Spring contacts / pogo pins on the board face (for reference):

   

4. Power the device (display USB-C)

Power for the entire device (Pi + display) comes in through the USB-C port on the display backpanel PCBA - not through a cable into the Pi’s USB-A ports.

1. Fit the 90° USB-C adapter onto the USB-C port on the display backpanel PCBA.

   

2. Connect a USB A-C or C-C cable to that adapter. Plug the other end into your 5 V / 3 A USB power supply (or leave it ready to plug in after the enclosure is closed).

   

Do not apply power yet if you still need to install the USB speaker (Option B).

The 180° USB-A adapter is only for Option B (speaker → Pi). It is not part of this power path.

5. Print the enclosure

Choose the MakerWorld print profile that matches your build (same model page, different profiles). Read the model page for the current file set and print settings. Enclosure files are under a separate license - see Credits and License.

Build	Print profile
Option A - without USB speaker	MakerWorld - no speaker
Option B - with USB speaker	MakerWorld - with speaker

---

Option A - Without USB speaker

Use when you do not want a wired speaker in the case. ATC / hourly chime can still use a Bluetooth speaker later via the portal, or you can leave audio disabled.

Print the enclosure without speaker profile.

Extra parts

None beyond the base BOM (no-speaker enclosure).

Assembly

1. Complete shared steps 1–5.

2. Seat the Pi + display stack into the printed enclosure so the round panel sits flush in the bezel.

   

3. Route the device power cable from the display USB-C pigtail (and Ethernet if used) out the rear opening. Leave USB-A ports free if you might add a speaker or dongle later.

4. Fasten the display / front to the enclosure with the 4× M4×8mm button-head screws.

5. Close any rear / bottom cover the print provides. Do not pinch the DSI ribbon or fan wires.

6. Power the device with a 5 V / 3 A supply into the display USB-C cable and continue with Software Setup (panel overlay, install-pi.sh, Wi‑Fi, API keys).

Audio later (optional)

After software install: portal → Bluetooth Speaker to pair a BT speaker for LiveATC and the hourly chime. See ATC audio and Troubleshooting.

---

Option B - With USB speaker

Use when you want ATC and the hourly chime through a USB speaker that the app can detect as an ALSA playback device (preferred default for the speaker gate).

Print the enclosure with speaker profile (speaker bay / baffle in the print files).

Extra parts

Qty	Item	Notes	Link
1	Compact USB speaker	Must enumerate as a USB sound device on the Pi. Fits the speaker enclosure cavity.	HONKYOB USB Mini Speaker
1	180° USB-A adapter	Male-to-female Type-A, 180° up-angled - plugs into a Pi USB-A port so the speaker can connect in the tight speaker enclosure.	Amazon B0C2CBZ28B

Assembly

1. Complete shared steps 1–5.

2. Before closing the case, plug the 180° USB-A adapter (Amazon B0C2CBZ28B) into a free USB-A port on the Pi, then connect the USB speaker to that adapter. This path is speaker-only (Option B) - separate from device power on the display USB-C.

   

   

3. Seat the Pi + display stack in the enclosure. Route speaker cable so it cannot pull on the DSI ribbon.

   

4. If the print has a speaker grille or pocket, align the speaker to it; otherwise position it where it will not rattle against the Pi or heatsink.

   ·

5. Route the device power cable from the display USB-C pigtail (and Ethernet if used) out the rear. Keep the speaker cable from being crushed by the cover.

6. Fasten with the 4× M4×8mm button-head screws and close the cover.

7. Power with a 5 V / 3 A supply into the display USB-C cable (budget headroom for panel + USB speaker).

8. Continue with Software Setup. After boot, confirm the speaker appears to the OS (aplay -l or portal audio status). Enable ATC Audio / chime on the web portal.

Notes

• Firmware prefers a USB (or selected Bluetooth) sink for ATC / chime. See .env.example (FLIGHTSCNR_REQUIRE_SPEAKER, FLIGHTSCNR_AUDIO_ALLOW_BUILTIN).
• You can still switch to Bluetooth later from the portal; use Use USB to return to the wired speaker.
• If sound is missing after reconnect, see Troubleshooting.

---

After assembly

1. Enable the Waveshare overlay and reboot - Software Setup#3-Enable-the-panel-in-firmware.
2. Run sudo bash install-pi.sh.
3. Open the portal, set location and API keys, and (Option B) verify ATC / chime playback.

Related

• Hardware - full BOM and links
• Software Setup - OS, overlay, software
• Web Portal - ATC, Bluetooth, favorites
• Credits and License - enclosure license