Jan 25, 2003 - Now that the board has been assembled it's time to put the package together. I've chosen a tin that used to house a Timex watch called the Expedition. This is where I get the name Rock-Mite Expedition. The tin measures 5 1/4" x 4 1/4", just the right size to install the radio, power regulator and some batteries. To start I will just install the radio and connections to the outside world. I purchased all my parts from Mouser Electronics. See the supplemental guide for a list of parts.
The hardest part of the whole project so far was drilling the holes in the thin metal. I used standard drill bits and slow speed on a hand drill. The tin bent a little and I messed up one hole a little bit. All in all the final product looks good. Just don't look to close (Picture 4).
The board is mounted with 40-4 x 3/4" Bolts with Nuts and 1/4 Long nylon spacers to mount the board inside the tin. The nuts, bolts and spacers were purchases at Home Depot for $2.09. With everything mounted and wired I was ready to smoke test the unit.