Choosing an Enclosure
Choosing an Enclosure
The enclosure protects your electronics from weather, UV, and physical damage. Choose based on IP rating requirements, available mounting options, and your willingness to do custom drilling and fitting. As a rule, target IP65 as the practical minimum for a sheltered outdoor enclosure, and IP66/67 for direct weather exposure.
IP Rating Guide
| Rating | Protection | Suitable For |
|---|---|---|
| IP54 | Under eaves, protected outdoor locations | |
| IP65 | Dust-tight, low-pressure water jets | Standard outdoor exposed deployment (practical minimum) |
| IP67 | Dust-tight, immersion 1m/30min | Ground-level, flood-risk, or harsh weather sites |
| IP68 | Dust-tight, continuous immersion | Underwater or buried applications |
Common Enclosure Options
Zulkit IP65 Junction Box - ~$12 (price as of 2026-06-08, varies)
Typically 150 × 100 × 70mm. Hinged lid with a foam gasket.gasket; Comesmany withlistings include two cable glands pre-installed.installed (confirm against the specific listing, as price, size, and included glands vary). Good balance of cost, size, and weatherproofing for a single-node solar repeater. TheA box this size accommodateswill accommodate a Heltec V3/V4, a charge controller module, and an 18650 battery holder.holder - confirm internal usable depth leaves clearance once mounted.
Generic IP65 - IP68 Junction Boxes - ~$10 - $15 (approximate, volatile)
Available in many sizes from AliExpress and Amazon. Quality varies; check reviews for gasket quality. At this price point, IP65 is reliable; IP68 ratings on cheap boxes should be treated skeptically.
Pelican 1300 - ~$1545 - $2060 for a genuine case (price as of 2026-06-08)
Durable, crushproof, watertight. Note that a genuine Pelican 1300 typically runs around $45-60 - figures well below $20 usually indicate a clone or used unit, so budget accordingly and check current pricing. Overkill for most deployments but excellent for portability or high-risk mounting locations. Foam insert must be cut to fit your components.
Ammo Can
Military surplus ammo cans are cheap, widely available, and extremely durable. TheIn plain terms: a metal box blocks radio signals, so the antenna MUST be outside the can on a bulkhead/feed-through connector - the steel construction provides RF shielding (keep the antenna outside), and the gasket provides good weather sealing.sealing, but it will detune or block a radio mounted inside it. Mount the board on stand-offs so it cannot short against the metal walls. Be aware that drilling and sealing a watertight antenna feed-through in steel is more work than in a plastic box. Replace the original gasket with EPDM for cold-climate use.use Conductive(EPDM enclosuresstays can affect radios - mount the node with stand-offsflexible to keeproughly it-40°C awayand fromresists the metal walls.ozone/weathering).
PVC Pipe Cap Enclosure - ~$3 - $5 (hardware-store pricing)
A 3 - 4 inch PVC end cap can house a minimal node (Heltec V3 + small LiPo + charge controller) and iscan surprisinglybe weatherproofmade water-resistant - not certified weatherproof, and with no IP rating - when the seams are sealed with PVC cement and silicone. BestThis foris compactan buildsunrated, wheread-hoc sizeDIY matterssolution. moreCaution: thando serviceability.not permanently glue or cement a lithium-cell node into a non-openable enclosure. You must be able to inspect and replace a swollen cell, and a sealed, cemented box gives a venting cell nowhere to relieve pressure - a fire-containment concern. For any lithium-powered build, prefer a gasketed, openable enclosure.
Muzi Works Injection-Molded3D-Printed Cases (PLA-CF)
Custom-designed for the Heltec V3.V3 Availableand available from Muzi Works directly. These are 3D-printed cases (carbon-fiber PLA per the product listing), not injection-molded. More form-fitting than generic boxes and easier to assemble, but more expensive. GoodA good option if you want a professional-clean-looking install without custom fabrication. Note that PLA-based filament UV-embrittles outdoors over time; treat it as a sheltered/semi-permanent solution rather than a long-term direct-weather enclosure.
3D Printed Enclosures
Community-designed enclosures are available on Printables, Thingiverse, Thangs, and Cults3D. Search for your specific device model. Print in PETG or ASA for outdoor use - ASA is the strongest UV/outdoor performer (Tg ~100°C), PETG is good (~80°C), and PLA degrades in UV and heat.heat (Tg ~60°C, embrittles outdoors) so avoid PLA for direct-weather parts. Seal seams and lid interfaces with food-gradeneutral-cure silicone.(non-acetic) silicone RTV - not acetic-cure aquarium-type sealant, whose acetic vapor corrodes copper. Add UV-resistant coating or paint to PETG prints for long-term outdoor durability.
Size Selection
Measure your components before ordering an enclosure. AAs a rough guideline, a typical single-node solar repeater (Heltec V3 or V4 + 18650 + CN3791) fits comfortably in a 150 × 100 × 70mm box. For a RAK WisBlock with larger battery packs, consider 200 × 120 × 75mm or larger. These figures are configuration-dependent - verify against your actual parts.
What to Avoid
- Generic "waterproof" boxes without an IP rating - these often fail in sustained rain
- Enclosures with screw-on lids that require tools to open - maintenance becomes annoying quickly
Clear/translucentPermanentlyenclosuressealing a lithium cell into a non-openable enclosure -UVkeepdegradeslithium builds serviceable