Features

The enclosure design has several features that take advantage of Fruit Jam. 

• Print-in place hinged backdoor with twist lock
• SD card slot in place of floppy drive
• 800 x 480 HDMI display
• Front speaker
• USB-C power with 2x USB-A ports, STEMMA QT and 3-pin JST port
• No support material required
• Top handle, Adafruit logo, snap fit bottom and front plate

CAD Assembly

The main assembly is available in Fusion 360 and STEP file formats. This includes all of the 3D printed parts and electronic components used in the project. Use the main assembly to create any edits, updates, or modifications. 

3D Printed Parts

Individual 3MF files for 3D printing are oriented and ready to print on FDM machines using PLA filament. Original design source may be downloaded using the links below. Use a black colored filament for the following parts.

• Display Mount
• SD Card Mount

Build Volume

The parts require a 3D printer with a minimum build volume of 162mm (X) x 176mm (Y) x 145mm (Z).

PLA Filament 

A white colored PLA filament works best for emulating the classic retro enclosures. A good options is Polymaker Panchroma Matte Cotton White.

Design Source Files

The project assembly was designed in Fusion 360. Once opened in Fusion 360, It can be exported in different formats like STEP, STL and more.

Electronic components like Adafruit's boards, displays, connectors and more can be downloaded from the Adafruit CAD parts GitHub Repo.

Parts

Gather up the parts and required fasteners for the build. 

Prep HDMI cable

Get the ribbon cable and two Right Angle (R bend) HDMI Plug Adapter ready.

Open the release latch from the two HDMI plug adapters.

Insert the HDMI ribbon cable into each end of the HDMI adapters using the flex cable clips.

USB-C Breakout Jumper Wires

Get two silicone covered jumper wires from the pack, preferably a blue and red colored set.

Using wire cutters, remove the connector from one end of each wire.

Then, solder the blue jumper wire to the GND (ground) pin on the USB-C breakout.

Solder the red jumper wire to the VBUS pin on the USB-C breakout.

Secure USB-C Breakout

Get the 3D printed USB mount, fasteners and USB-C breakout ready.

Use four M2.5 x 6mm long machine screws to secure the USB-C breakout to the USB mount.

Double check the breakout has been correctly mounted to the 3d printed part.

Prep PicoBlade Cable

Get the matching pair of the 2-pin picoBlade cables ready to solder together.

Cut two pieces of 30AWG heat shrink tubing and slip them onto one set of the picoBlade cables. One of each wire. 

Using helping hands, prop the wires up so their overlapping.

Join the matching wires from the two cables by soldering them together.

Slip the pieces of heat shrink over the solder joints and apply heat to shrink.

Set the assembled picoBlade cable aside.

Install Door Latch

Rotate the print-in-place door knob on the main enclosure so its orientation matches the assembly photo.

Place the 3D printed door latch onto the door knob with the two mounting holes lined up.

Use two M2.5 x 6mm long machine screws to secure the 3D printed door latch to the knob on the main enclosure.

Test the door knob by twisting it on the other side of the case. It should be able to lock and open the print-in-place door.

Install USB-C Adapter

Get the USB-C Panel Mount Adapter ready to install into the 3D printed base.

Remove the threaded nut from the body of the USB-C adapter by unscrewing it.

Insert the USB-C adapter into the circular hole on the side of 3D printed base with the various cutouts.

Fasten the threaded nut back onto the body with the wide flange facing away from the surface of the base – This will allow the bottom cover to set flush with the base.

Secure Fruit Jam

Get the Fruit Jam, fasteners and 3D printed PCB mount ready to assemble.

Place the Fruit Jam over the 3D printed PCB mount so the mounting holes are lined up correctly – one of the standoffs features a pin that will fit into the mounting hole that doesn't have a soldered standoff.

Insert and fasten three M3 x 8mm long machine screws to secure the Fruit Jam to the 3D printed PCB mount.

Secure PCB Mount

Get the Fruit Jam with the PCB Mount ready to secure to the 3D printed bottom cover.

Place the Fruit Jam onto the bottom cover so the USB ports are facing out and the mounting holes are lined up.

Insert and fasten four M3 x 8mm long machine to secure the PCB Mount to the bottom cover.

Install Rubber Bumpers

Select your preferred size of rubber bumpers to attach on the bottom cover. (I used four of the 0.6" sized rubber feet from the assortment kit).

Use your preferred adhesive or double-sided tape to attach the bumper feet.

Secure 5in Display

Get the 5 inch HDMI display, fasteners and 3D printed display mount ready to assemble.

Orient the 5" HDMI display with the display mount so it matches the assembly photo.

Place the 5" HDMI display onto the display mount so the mounting holes are lined up with the standoffs.

Insert and fasten four M3 x 6mm long machine screws to secure the display.

SD Adapter Prep

A spudger prying tool will be used to disassemble the plastic injection molded case of the SD card adapter. 

Using the prying tool, slide the edge in between the halves of the enclosure.

Pop open the enclosure and remove the PCB of the SD card adapter.

Discard or set aside the halves, they won't be needed in this build.

Secure SD Card Adapter

Get the SD card adapter PCB, fasteners, 3D printed SD card cover and front panel ready to assemble.

Orient the 3D printed SD card cover with the SD card adapter so it matches the assembly photo.

Place the SD card cover over the SD card adapter PCB. 

Place the SD card adapter assembly over the built-in mounting plate on the 3D printed front. 

Insert and fasten four M3 x 8mm long screws to secure the SD card adapter assembly to the 3D printed front panel.

Test SD Card

Insert an SD card to the SD card adapter through the slot on the 3D printed front panel.

Push in the SD card to actuate the spring-loaded mechanism to eject the SD card.

Secure USB-C Mount

Get the assembled USB-C mount, fasteners and display mount ready to assemble. 

Place the USB-C mount over the built-in standoffs on the 5" HDMI display so the mounting holes are lined up.

Insert and fasten four M2.5 x 6mm long machine screws to secure the USB mount to the display.

Secure Display Mount

Get the display mount, fasteners and front panel ready to assemble.

Place the display mount over the standoffs on the front panel so the mounting holes are lined up.

Insert and fasten four M3 x 6mm long machine screws to secure the display mount to the front panel.

Install USB-C Cable

Get the 100mm long USB-C cable ready.

Plug-in one end of the cable to the USB-C port on the 5in HDMI display and the other end to the USB-C socket on the USB-C breakout.

Connect HDMI Cable

Insert one end of the HDMI cable to the 5" HDMI display so the ribbon cable is facing out away from the front panel.

Join Base to Case

Get the 3D printed base, fasteners and case ready to assemble.

Orient the base with the case so the side with the various cutouts are facing the side of the case with the door.

Join the two parts together so the four mounting tabs are lined up.

Insert and fasten four M3 x 8mm long screws to secure the two parts together.

Install On/Off Switch

Get the switch and switch clip ready to install into the case assembly.

Insert the switch into the matching cutout on the base.

While holding the switch in place, slide the switch clip on so the grooves are lined up with the notches. This will keep the switch in place and prevents it from fall out of the base.

Test the switch by sliding it to the left and right. It should freely slide between the two sides.

Install Speaker

Get the mini oval speaker ready to install into the base.

Remove the protective cover from the front size of the mini oval speaker by peeling it off.

Position and place the mini over speaker into the cavity built-into the base. Gently press on the speaker to adhere it into place.

Join Front to Case

Get the front panel assembly and case assembly ready to snap fit together.

Orient the two parts and place the various cables inside the case.

Firmly press the two parts together to snap fit them shut.

Connect PicoBlade Cable

Lay the assembled case on its side and grab hold of the cable from the speaker.

Connect the 2-pin picoBlade cable to the speaker.

Connect USB-C Cable

Get the bottom cover and 150mm long USB-C cable ready.

Plug in one end of the USB-C cable to the USB-C panel mount adapter.

Then, plug in the other end of the cable to the USB-C port on the Fruit Jam.

Connect SD Card Adapter

Grab hold of the micro SD card adapter cable and connect it to the micro SD card slot on the Fruit Jam.

Connect Speaker

Grab hold of the cable from the speaker and connect it to the speaker audio port on the Fruit Jam.

Install Bottom to Case

Orient the bottom cover with the case assembly so the various ports on the Fruit Jam are facing the various cutouts on the base.

Take note of the position of the 3D printed switch with the built-in switch on the Fruit Jam. They ought to be in the same position.

Insert the bottom at an angle so the USB-A ports are fitted through the rectangular cutouts on the base.

Firmly press the two parts together to snap fit them closed.

Connect USB-C Jumpers

Unlock the latch from the door on the case to open it.

Grab hold of the two jumper wires from the USB-C breakout.

Plug the red jumper wire to the 5V header pin on the Fruit Jam, then plug the blue jumper wire to the GND pin.

Close Door

Ensure all of the cables are inside the case.

Close the door and twist the knob to lock the door latch.

Build Check

Take a moment to inspect all sides and various ports on the enclosure.

Install SD Card

If you haven't already, pop the SD card into the slot. Any files, ROMs and code should be loaded on the card prior to insertion.

Boot Loader Mode

Go into boot loader mode to install new firmware on the Fruit Jam. To do this, you'll want to open the back door and follow the sequence.

To enter the bootloader, hold down the BOOT/button #1 (highlighted in red above), and while continuing to hold it (don't let go!), press and release the reset button (highlighted in blue above). Continue to hold the BOOT/button #1 until the RP2350 drive appears!

If the drive does not appear, release all the buttons, and then repeat the process above.

A lot of people end up using charge-only USB cables and it is very frustrating! Make sure you have a USB cable you know is good for data sync.

Connect Power, Mouse and Keyboard

To power the Fruit Jam, use a USB-C cable and connect it to either your computers USB hub or 5V USB power supply.

Connect your preferred keyboard and mouse to the USB-A ports on the Fruit Jam.

Switch On/Off

Use the 3D printed switch to power the Fruit Jam on or off. Slide to the right to power on. Slide left to power off.