RPI Zero 2w + WD Elements 4TB HDD, Casing, Housing, Libreelec, Kodi

Use a piece of filament for the hinge.

The device is working ok for smaller files 720p 1080p h264. I would say max 5gb files.

Mild overclock is necesary, libreelec and a light theme for kodi like quartz. 

Disable all animations etc, hw acceleration also, limit gui resolution to 720p, refresh rate to 50hz, set caching to 1.1x 20mb. Thats my setup and it works ok. 

Be carefull when loading bigger files as it wil freeze if you touch it to much , wait a bit to load properly. 

I use it as a offline movies and tv shows library. Fan is connected to 3.5v it is enough for my needs and also because of power draw. I use a laptop usbc charger with a adapter for micro usb as the hub is micro usb also. 

If you have any tips to make it faster let me know. i know with separate powering hdd and pi it would be better but that is overkill with 2 power sources. 

Install libreelec for rpi zero 2w via raspberry pi imager app

Max overclock voltage is 4 for me. Anything above draws too much power and it freezes a lot. 

To start libreelec at all you must add this line to config.txt:

dtoverlay=cma,cma-256

my overclock setup is: (just add it at the bottom of config.txt)

arm_freq=1200
core_freq=450
gpu_freq=450
sdram_freq=450
over_voltage=4
 

I used following parts: 

1- Raspberry pi zero 2w with presoldered gpio headers

2- Auvpal usb hub

3- Raspberry 5 heatsink with fan, i used only the fan

4- Geekworm Raspberry Pi Zero 2 W Heatsink

5- SMALLRIG micro hdmi to hdmi female adapter

6- USB to HDD 90 degrees cable

You need some screws and melting thread inserts also. I used this 

1- Screw Set M2

2- Thread inserts M2

when the top is closed you screw one screw at the front to keep it closed if you like. 

Stl files are all orientated to use minimum supports. The bottom part doesnt need ones. Top only need support at the bottom, use a brim 20mm for safety.