Source code available at https://github.com/ambrogio-galbusera/gr0g, https://github.com/ambrogio-galbusera/gr0g-ble-android and https://github.com/ambrogio-galbusera/gr0g-ble

In this post we will finally start building the frame of Gr0G box

Building the top and bottom panels

Parts list

To build the top and bottom panels, you need

8 pieces of bar with LED housing 46 cm in length with 45 degrees cut on both sides (when cutting, keep the LED housing facing upside)
8 clamps. I got my clamps from an L-shaped 40 mm x 40 mm x 1.5 mm aluminum bar. I cut 8 pieces of 20 mm in height
Rivets (16, at least). I used 3 mm rivets, so I drilled the parts with a 3.3 mm bit
a 46 cm x 46 cm plexiglass
8 M4 x 20 mm screws with bolts

How to proceed

Drill two holes for each side of the clamps (4 holes per clamp, in total). Try to stay on the middle of the clamp (see picture) because the section of the bar with the LED housing is irregular and you will get a better result if stay 10 mm from the border

Mate the clamp with the aluminum bars and fix the parts with 2 rivets per side

With a 4 mm bit, drill 2 holes for each edge of the frame, close to the corner in order not to interfer with the LED strip we will install later. Drill the holes close the inner edge of the aluminum bar or you will not have enough room for the bolt

Screw the screws and bolts

Building the four lateral panel

Parts list

To build the four lateral panels, you need

4 pieces of bar with LED housing 50 cm in length
4 pieces of L-shaped 30 mm x 20 mm x 1 mm aluminum bar 50 cm in length (referred as bar "A")

4 pieces of L-shaped 20 mm x 20 mm x 1 mm aluminum bar 50 cm in length (referred as bar "B")

4 pieces of 30 mm x 1 mm aluminum bar 50 cm in length (referred as bar "C")

Rivets. I used 3mm rivets, so I drilled the parts with a 3.3 mm bit
4 50 cm x 50 cm plexiglass
16 M4 x 20 mm screws with bolts

How to proceed

Drill holes in bar "A" as shown in picture
Mate the bar "A" with the LED aluminum bars and fix the parts with 2 rivets
Drill holes in bar "B" as shown in picture
Mate the bar "B" with the LED aluminum bars and fix the parts with 1 rivet
Mate bar "C" with bar "A" leaving 20 mm from the edge of bar "A"
Mate bar "C" with bar "B" leaving 20 mm from the edge of bar "B"
Put the plexiglass in place and, with a 4 mm bit, drill 2 holes in bar "A" and two holes in bar "B"
Screw the screws and bolts

Joining panels

Parts list

To join the panels, you need

10 joints with a maximum height of 20 mm
30 countersunk head screws and bolts

How to proceed

Take the bottom panel
Place the joint on the bar with LED housing, drill an hole for the screw and fix
Place one of the side panels with the plexiglass facing upside. Place the joint as shown, drill two holes for the screws and fix