Since I would like to see more of these system implemented in the area, I thought it would be good idea to document at least one way to design and build an outdoor enclosure for a WRT54GL router. I also wanted to make sure that the parts I used were locally available.
Below is a list of materials needed for this installation:
Linksys WRT54GL Wireless Router (Available new and used from many sources)
Orbit Irrigation Products Sprinkler Timer Enclosure Model 57090 (Available from Lowes or Home Depot)
Below are a list of tools that I used in the build of this system:
Phillips Screw Driver
Dremel Type Tool with Cutoff Wheel
How I Did It
There is no right or wrong way to do this. Below are the steps that I followed. This is one of these projects that is just begging for ham radio improvisation. So feel free to try new things.
Step 1 Modify the Box
There is no right or wrong way to do this. Below are the steps that I followed. This is one of these projects that is just begging for ham radio improvisation.
Well here is the box as you get it from the store.
Here are several views of the exterior of the box.
When you first open the box here is the view.
Here are a few more details of the interior. Notice the latch and GFI outlet. The box also has an intermediate cover plate that will be removed.
With the GFI outlet removed you can see that the WRT54 will just not fit. So, let the modifications begin.
So with a Dremel type tool and a small saw, I removed the center support post and the plastic around the GFI outlet. The fit is much better now. With the antennas installed it fits just fine. For the installation I have in mind, one of the antennas will be removed an an external antenna used.
Here is a picture with the locking latch installed. The latch does not have to be latched to operate.