CW Hotline includes a case, but it must have holes drilled and cut. A drilling template should be printed out at
100% size. Don’t print with “Fit to page”.
Case Parts
CW Hotline case
Printed case drilling / cutting template
4 - M2.6 x 8mm black screws
Vinyl label
Case Tools Needed
Scissors
Tape
X-acto knife / Safety pin
Drill with 5/64”, ⅛”, 5/32” ¼” (2mm, 3mm, 4mm, 6mm) drill bits
Emery board
Case Assembly
Measure the 1” or 2 cm reference square on the template to ensure it was printed at the proper scale.
Cut out the template cross shape on the outer solid lines.
Remove the thin bottom plate of the case and set it aside. Wrap the template around the outside of the
case such that the 4 edges of the template just reach the edges of the case. Use tape to secure the
template to the case.`
Use a safety pin or knife tip to mark/dimple the centers of the holes. There are 10 holes on the top, 3
on the long side, and 2 overlapping holes on the short side.
If including the straight key or paddles on the PCB, use an X-acto knife to mark the location of the
rectangular hole on the other short case side, along the dotted lines.
Remove the template and tape. The template will help to reference hole sizes.
Drill out all 15 holes with the 5/64” / 2mm drill bit.
Enlarge the LED, button, and side holes with the ⅛” / 3mm drill bit. Do not enlarge the 7 speaker holes.
Enlarge the button and side holes with a 5/32” / 4mm drill bit. Do not enlarge the other top holes.
Enlarge the 5 side holes with the ¼” / 6mm drill bit. To avoid cracking the case, step up through
multiple intermediate bit sizes 1/32” / 1mm at a time or use a step bit.
Use an X-acto knife to convert the 2 holes on the short side to an oval that will accept the USB cable. A
Rat tail file may help.
If including the straight key or paddles on the PCB, use an X-acto knife, hacksaw, or nibbler tool to
remove the rectangular hole on the case side. Be careful with this step! Sewing thread can also work
as a cord saw. Smooth with a file or emery board.
After PCB is assembled (see instructions below)
Enlarge holes as necessary to fit the PCB into the
case.
Secure PCB to case with 4 screws in the corner
holes. Do not over tighten or the plastic may crack.
Close case with the removed plate, with the notched
end near the rectangular hole.
Apply vinyl label.
