Heltec ESP32 LORA case

Case for the Heltec esp32 lora board. It must be the version without header pins installed. Perfect for Meshtastic.
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updated July 23, 2023

Description

PDF

Lithium batteries are dangerous. Be safe and research safe lithium polymer battery handling before building. I am not responsible for injury or accidents that may occur related to this device, its use, or assembly.

Hardware

2x M3x15 screws (M3x16 works too)

2x M3 nuts

1 piece of wire cut to 18mm (you can drill or heat set hole within reason)

1x Small piece of 3m adhesive, or double sided tape to prevent battery from rattling

1x Heltec Esp32 Lora V3 (print fits older versions, but meshtastic doesn't support them)
WITHOUT PINS SOLDERED ON!!! Be sure to get the LORA version. They have identical ESP32 without lora

1x 1000mAh Lithium battery w/ jst1.25 connector 
https://a.co/d/a2cZ78a

1x UF.L Lora antenna (3.5mm outer diameter) 
https://a.co/d/i70CdGs
https://www.aliexpress.us/item/3256805425337390.html?channel=twinner


Do not put wire into button/lid until you verify button moves freely, and doesn't stick
If button sticks, lightly sand or file until it moves freely.

Print at .2mm max layer height. 
Reference photo for ideal print orientation

Assembly:
After verifying button moves freely in lid, bend wire slightly, cut to length, and install. If wire feels loose, use a magnet and smack the lid against the magnet to free wire. 
If wire remains stuck, its likely tight enough to leave alone.
Install antenna into lid, and then connect to ESP32. 
You can add a small bit of silicone to the antenna at the base of the heatshrink, where it widens to seal the antenna into the lid.
Carefully install ESP32 microcontroller into lid so that antenna makes nice sweeping loop in top of the lid. (no hard bends)
Pass battery wire through "Mid" being sure orientation is correct (round edge near antenna and screw holes line up)
Place a small piece of adhesive on "Mid" SMALLer is better in case you don't align the battery perfect on assembly you can move it around. There is some room for error, but not much, and peeling a huge chunk of 3m adhesive can have you concerned for your fingers (LIPOS ARE DANGEROUS) 
Connect battery to esp microcontroller and carefully seat ESP32 into Lid
Sandwich Lid with Mid, being careful not to force anything. If screen fits too tight you will crack screen and it will be useless. (I know from experience. Screen totally died, but device still worked otherwise) You can file where necessary
Slide battery cover on careful not to pinch, pull, or bend wires. 
Once holes line up insert screws and nuts. Tighten uniformly/evenly

Then you are free to update the device with a usb C cable to whatever you want to use it for.

It has been working great for meshtastic so locals can communicate in areas that have no reception.
It is limited to text messages w/gps and other capabilities. It is not fast enough for voice, but gets remarkable distances.

https://meshtastic.org/docs/getting-started

Follow your local laws. In most areas this should be low powered enough that no licensing is needed, but be sure before proceeding.

 

 

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