5. Router Card

The Inkscape .svg provided for this card is intended for the Linksys/Cisco WRT310N V1. The WRT310N V2 would also be a fine choice, except that my card design would require modification. Don’t be shy about modifying my design to work with a different router’s guts. I can’t even guarantee that every WRT310N V1 is the same, so you may be stuck modifying the card design even if you get the same model and revision.

Step 1. Install Third-party Firmware (Optional)

I highly recommend installing a third-party firmware before modifying your router to be installed in a card. DD-WRT, while imperfect, still provides a lot of options that are lacking from the OEM firmware. There are guides available that can tell you how to do this. At the very least, I also recommend having a spare router available, in case you brick the first one. (Even if you’re careful, it can happen.) If you buy them used, these should only cost about $10-$20, so it should not be a big expense to have a spare available.

Step 2. Modify the Card For SATA Power

SATA provides 3.3V, 5V, and 12V taps. Most likely, your router will need 12V for power. Remove the power jack from its main board and install a power wire in place of it. Given that the router is likely to be one of the components that’s sensitive to electrical interference and is also a transmitter, I recommend using thin coaxial cable for this part. That should minimize the chances of feedback from its transmitter to its power.

Or, if you want to be a little lazier in this step, you can just cut the last few inches off the original wall wart power supply to use as a cable. The jack won’t need to be removed if you do this.

Router Card - Circuit Board Modification - Detail 1 Router Card - Circuit Board Modification - Detail 2

Solder the other end of the cable to the SATA power adapter you created in part 1. If you’re uncertain about the length of cable you’ll need, wait until you have the tray done before you cut the wire to length. Also, leave a little extra wire so it can give a little while you’re installing it; this cable doesn’t need to be tight.

Router Card - Power Board

When the parts are finished, you’ll have a tray, a top, and a router board that’s been modified to use a SATA cable for power.

Step 3. Laser Cut and Glue Acrylic Parts

The process of cutting and assembling the parts for this card is essentially the same as the process for the power cards. Please refer to that step if you have any questions about the general procedure for assembling these cards.

Router Card - All Parts Assembled

Step 4. Assemble the Finished Card

Assemble it with zip ties the same way you did with the other cards.

Router Card - Fully Assembled Router Card - Fully Assembled

4. Raspberry Pi Cards 5. Router Card 6. Ethernet Switch Cards

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