ADHDv3 ADS-B Cooled Enclosure

I needed a way to cool both my ADSBex dongle and RPI Zero 2W so I designed this box, with a Noctua 60x25 5 volt fan in mind. My Pi's operating temperature dropped from 57C without a fan, with a small heatsink, to around 30C with the same heatsink and the Noctua NF-A6x25 fan (photo).

To prepare, you will need:

• Raspberry Pi Zero 2W or Zero 2WH (an original Zero W is not recommended)
• Either the blue or green ADSBexchange SDR dongles (heat sink optional but suggested)
• USB OTG cable, at least 6" long
• Noctua NF-A6x25 5 volt fan (5 volt is important as the fan will be powered by the Pi)
• 4x fan mounting screws
• 4x M2.5 8mm screws (I prefer flat head, for mounting the Pi Zero 2W)
• a small tool to remove a pin from the Noctua fan connector (or scissors/nipper)
• if you have a headerless Pi Zero 2W, two .1" header pins (and tools to solder it in place)

Instructions for assembly:

1. If you have a Pi Zero 2 W you will need to install header pins for the 5v and GND pins.  There are many how-to's on YouTube and elsewhere describing how to do this.  
2. Using a very small flat blade screwdriver, remove the yellow wire from the fan power connector (or cut the yellow wire at the connector) and tape this to the fan cable sheath, we will not need this connection.  
3. Install the Pi Zero 2W with four M2.5 8mm screws to the bottom case.  
4. Connect the fan power connector to your Pi, then mount and screw the fan into the bottom case, making sure to orient the fan so it is blowing air into the case (the label should be inside the case, not visible from the back).  
5. On the ADSBex dongle you can fit heat sinks on either side up to 50mm long and 10mm tall. Make sure to use thermal tape to stick heat sinks on the bottom heat sinks (facing the Pi).  Slide the dongle in from the front, it will be a little tight but will slide easily once started and will sit inside the opening.
6. Attach the USB OTG cable to the dongle and plug into the inner USB Micro port on the Pi Zero 2W.

You're now set to power on the Pi and install your ADSB software of choice, my preference being the suite provided by Wiedehopf at their GitHub.

NOTE:

You will need to perform a planar cut on this design about 35mm from the bottom of the box  and rotated 270 degrees on the X axis (red handle) with the fan side on the bed (photo).  For the pegs, for example, in PrusaSlicer you should place snap pegs 5.5mm deep, 3.5mm in size, with a 90 degree rotation, 15% bulge, and 20% space between the peg sides, each centered on the bulges in the box sides (photo).  Split keeping the print orientation.  Sorry I have to do this, but PrusaSlicer won't export a split STL with the snap pegs already in place. :(