I recently finished my 2 units as well. I took them for the first sail yesterday in the final configuration. I just thought I would write up my experience as well.
All bits for the board where bought from Allie express. Everything turned up pretty quick. I did get caught out buying a non branded gps module. Fortunately I found out before it was sealed up with epoxy. Just make sure when searching for the gps search for "Beitian BN220" and not just "BN220". The branded gps seems to pick up about 26-29 satellites as opposed to about 15-20 with the non branded one.
I found it very tricky at the start shouldering up the connections at first as I had probably not shouldered anything for about 20 years. I could having a large magnifying glass/light helped a lot. I bought one off Allie express. Using it I could I could just do all the shoulders on a flat surface. I didn't need a vice. I also managed to brake a reed switch trying to bend the wires into shape. I learnt to only bend from the wire end and not the glass.
I also found not having too much excess wire left after connecting everything made it fit in the box much nicer. Even cutting the wires for the gps module different lengths depending on how far from the slot made a difference.
I also managed to burn out the fuse on the board that connects the battery and had to shoulder the battery to the VBAT connection and a ground. I didn't have much luck shouldering the wireless charger to the board and settled for extending the wires on the wireless charging pad and plugging it into the micro USB port.
I only have Linux on my computers at home so I had to get a friend to load the firmware the first time using windows 10. I did spend. A morning having a crack with a very old copy of windows 7 but couldn't get it to work. It was pretty straight forward on windows 10 and worked just about first go from memory.
my friend also had a 3d printer so I got 2 of flex's boom mounted boxes made up. I can't really comment on how hard the 3d print part of the project was as I wasn't really involved. My friend said he just loaded it up and walked away though so it must have gone pretty smooth. I'm not sure what type of printer he used.
I had a bit of running around to do to find the 3mm polycarbonate face glue and potting epoxy. I think I messaged flex about 6 times trying to figure it out.
I ended up getting it from a crew on the Southside of briz called acrylics online. They also had the glue called weld on #16. I did find the Dichloromethane for sale on line but the weld on worked well. I ordered the potting epoxy off eBay.
All the bits fitted into the 3d case pretty well with a bit of a light sanding. I also coated the outside of the case in epoxy to seal it as that was about all I had and it seemed to work ok. I bought a dermal tool as well which is really handy. I sanded the edges of the polycarbonate face to try and get a good bound with the case and it seemed to work ok. I just lightly clamped them.
The potting epoxy was good as well. It had a long cure time. About 72 hours I think. One of the cases l leaked from around the faceplate I think so it needed to be topped up a bit. I had to top up the unit once it had cured a bit as well. I used a couple of syringes I bought from chemist warehouse for 40c each. They where only small at about 5ml I think. There where a few air bubbles in the cases but they mostly came out. One one of the units there are a few really small ones over the screen. They don't cause any problem reading the screen. The other one was clear.
Lastly I gave them all a bit of a sand and bought some bungee cord from Bunnings to attach them to the boom. I just tied the bungee cord together. I don't know if you can buy small loops of it pre joined or not.
thanks to jan for doing the hard work writing the software and design and flex for the 3d case and advice to try and assemble it. I really enjoyed the process and I would encourage anyone interested to have a go building one. If anyone in the briz area would like help just let me know and I would be happy to. You can borrow what ever I have here.
thanks Shannon.