I started by measuring the inside dimensions, and cut a piece of 1/8" luan board., that I then spray painted gray.
I cut out pieces of thin cardboard the size of the power supply and LOR DC card to be able to slide them around to determine the best layout positions.
Then I discovered the RJ45-ECS connectors. While adding to the cost of the project, I liked the idea of having the luxury of making all the connections for the floods and RS-485 data from outside the box, without having to even open the case. This was the path I took when building version 2, and the later reto-fitting of the version 1 box.
The RJ45-ECS connectors require a 7/8" hole for mounting, and provide weather proof connections
An alternative, and probably much less expensive method would be to just use a standard RJ-45 plug and a RJ45 coupler.
The case I used is the Keptel CG-1500
Photo Credit - YBBS website
Next I fabricated brackets to use in mounting the power supply. I used a 1" X 5" galvanized metal Simpson tie plate obtained at Lowe's in the lumber section for about 50 cents. Both brackets were made from one plate.
Simpson part number is TP15. I used metal shears to cut the plate in half, then bent a lip in the vise. Drilled additional holes to match the power supply mounting and in the lip for mounting to the luan base. I did use the bench grinder to round over the edges
I used 6-32 nuts and bolts for mounting the power supply and the LOR card. Then I used 8-32 self taping sheet metal screws for securing the luan mounting board to the case standoffs.
The first version of the case I used a 4 port keystone plate and jacks for the cat5 connections.Click here to add text.