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

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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.