UPDATE 17/05/2020 - Receiving requests for files so added all F360 document files and STEP files. The F360 files might be a little bit of a mess with the workflow and I didn't name everything so might take some picking apart. Sorry, it was my first year learning design. There is an F360 file for a multi material model. the top half has been split into sections, just the bottom half needs the same to finish it off. I just don't have the time.

https://youtu.be/YPPz0QWnRAw

The model I've printed, I use a filament change (M600) to make the top and bottom different colours. Multi-part model coming soon for people with dual extruders/MMU/Palette

Inspiration for the layout came from my favourite Pi 3b on here (https://www.thingiverse.com/thing:3714695), and the Pi 4 remix helped getting the ports lined up first time, so thanks for that.

For the GPIO to break out, make sure "Detect bridging perimeters" is unchecked in PrusaSlicer under Print Settings->Layers & Perimeters

You will need:

Tools - 2mm Allen Key, Phillips screwdriver (fan screws)

• 4 - M2.5 x 20mm cap head screws for slim version, M2.5 x 25mm for fan versions

• 4 - M2.5 nuts

• 6 - 8mm rubber feet (optional, links below)

Screws for the fan openings:

For 30mm x 30mm x 10mm fan

• 4 - M3 x 14mm pan head screws

• 4 - M3 hex nuts

For 40mm x 40mm x 10mm fan

• 4 - M4 x 14mm pan head screws

• 4 - M4 hex nuts

(You can only fit a 10mm fan inside the case. For deeper fans, mount outside and adjust screw length to fit)

For the slim case with no fan opening and the 30mm case with fan mounted outside, Ive used a 25mm x 25mm x 10mm heatsink, it fits in there nicely. If you're going all out with cooling, in the 40mm fan case you could fit a 25mm x 25mm x 15mm heatsink only if you position it correctly so it doesnt hit the nuts holding the fan.

Links:

8mm rubber feet:

• https://www.ebay.co.uk/i/172638753096?chn=ps&var=471450955180&norover=1&mkevt=1&mkrid=710-134428-41853-0&mkcid=2&itemid=471450955180_172638753096&targetid=519877050926&device=c&adtype=pla&googleloc=1007055&campaignid=1782815745&adgroupid=70885937482&rlsatarget=aud-629407027665:pla-519877050926&abcId=1139356&merchantid=113597075&gclid=Cj0KCQjwyLDpBRCxARIsAEENsrJCXMxnxey71p6uGZKu0FfZvikMFaxztG99ScKG5EKu5QmVj1WH_cYaArCdEALw_wcB

25mm x 25mm x 10mm heatsink:

• https://www.ebay.co.uk/itm/362590807424

25mm x 25mm x 15mm heatsink:

• https://www.ebay.co.uk/p/Aluminium-Heat-Diffuse-Cooling-Fin-Heatsink-25mm-X-25mm-X-15mm-10-Pcs-Black-M-El/26011621743?iid=323273460847&chn=ps&norover=1&mkevt=1&mkrid=710-134428-41853-0&mkcid=2&itemid=323273460847&targetid=604156787033&device=c&adtype=pla&googleloc=1007055&poi=&campaignid=1506022780&adgroupid=59527570553&rlsatarget=aud-605072137101:pla-604156787033&abcId=1139586&merchantid=101713788&gclid=Cj0KCQjwyLDpBRCxARIsAEENsrKjN10yF0mw-JMhgA_dIgvibRwE5mL3YUaXIVkhflopSrfNYWTO5GoaAjtmEALw_wcB

Im not affiliated to these sellers. Just some "cool" options :P

The holes for the screws and nuts might need a little clean up. When you place the M2.5 nuts in the bottom half of the case, screw the M2.5 bolt through the bottom half only until tight to help pull the nut in so its aligned properly.