VHF Ham Radio Ammo Can Go Box / Portable Field Radio Station

Designer

hixreate

Designer relation

Ingen

Kategori

Electronics

Licens

Creative Commons Attribution NonCommercial ShareAlike Creative Commons - Attribution - Non-Commercial - Share Alike

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Designer commercial

None

Først set

2026-09-17 00:20

Sidst set

2026-09-18 08:20

Tags

3d printed electronics amateur radio amateurradio ammo can ammo case ammo container DIY Electronics Enclosure electronics enclosure electronics-enclosure emcomm emergency communications emergency communications equipment field radio Go-box Ham Radio hamradio portable radio radio vhf vhf uhf yaesu Yaesu FT-1900

Beskrivelse

This is a compact VHF radio go-box built around a Yaesu FT-1900 and installed in a metal .50-caliber-style ammo can. The goal was to build something more complete than a basic radio mount: a self-contained portable station with active cooling, selectable audio/data connections, an internal speaker, front-panel protection, and enough storage to keep the microphone and essential cables with the radio. Most of the internal structure and front panel are 3D printed, allowing the electronics to be mounted cleanly inside the enclosure. The finished box includes: Yaesu FT-1900 VHF mobile radio Dual-fan cross ventilation Independently switchable headphone output Independently switchable external speaker Independently switchable data/audio port Adjustable output level for the data port Single-LED miniature VU/activity indicators for the headphone and data outputs 3-watt front-panel speaker Front-accessible blade fuses Independent power/control switches Microphone connection accessible from the front Internal storage compartment for the microphone, power/data cables, adapters, etc. 3D-printed radio mounting, front panel, and internal divider components The idea was to keep the radio protected during transport while still making it possible to set the box down, connect DC power and an antenna, open the lid, and immediately have a usable VHF field station. Design The radio occupies the upper portion of the main equipment panel, with the supporting electronics arranged beneath it. The front panel provides access to the controls that are most useful in the field without requiring access to the inside of the enclosure. A separate compartment on the right side is used for cable and microphone storage. This keeps loose equipment from resting against the radio, fan, or wiring during transportation. One of the more important parts of the design is the cross-flow ventilation system . A fan in the front equipment panel works together with a second fan mounted on the internal side/divider panel to move air through the enclosure instead of simply circulating hot air inside the can. The FT-1900 is a fairly substantial mobile radio, so airflow was something I wanted designed into the box rather than added afterward. Audio / Data System The box has separate outputs for: Headphones The headphone output can be enabled or disabled independently so headphones can remain connected without automatically affecting the rest of the audio system. Speaker The front panel contains a 3-watt speaker for normal portable operation. Data / Audio Output A separate switchable port provides audio for external equipment. Its output level has its own volume control so it can be adjusted independently of the listening volume. Small single-LED level/activity indicators are also built into the headphone and data circuits. They aren't intended to be precision meters; they're simply a quick visual indication that audio is present. This arrangement makes the box useful for more than basic voice operation and gives access to radio audio without having to modify the installation every time another device is connected. Cooling There are two fans arranged for cross ventilation : One mounted in the main front panel One mounted in the internal divider/side panel This creates an actual airflow path through the equipment area. If you're adapting the design for another radio, pay attention to the location of the radio's heatsink and orient your fans accordingly. Power and Protection The radio and accessory circuits are protected by front-accessible automotive blade fuses . I specifically wanted the fuses accessible without dismantling the enclosure. If something fails in the field, replacing a fuse shouldn't require removing the entire front panel. The various accessory systems also have their own front-panel switching so unnecessary loads can be shut down when they aren't needed. Storage Compartment The open compartment beside the electronics panel is intentional. It provides space to carry things such as: FT-1900 microphone Programming/data cable Audio cables Small adapters Power accessories Other radio-related odds and ends Keeping that space separate from the electronics also prevents the microphone and cables from bouncing around against the radio and cooling system while the box is being transported. Printed Parts The uploaded models make up the basic internal structure of the box. The major printed components include: Main front/equipment panel FT-1900 radio support/mount Internal divider/fan panel Important Check the fit against your particular ammo can before drilling anything. “.50-cal ammo can” is not a precision enclosure standard. Different manufacturers and reproductions may have slightly different internal dimensions, hinge geometry, wall shapes, and tolerances. I designed these parts around the enclosure I had. Print Settings Suggested settings for a build like this: Material: PETG, ASA, ABS, or another reasonably temperature-resistant material Layer height: 0.20-0.28 mm Walls: 4 or more Top/bottom layers: 4-6 Infill: Approximately 25-40% Supports: As required depending on orientation Nozzle: 0.4 mm works well, although a 0.6 mm nozzle is perfectly reasonable for the larger structural pieces I would not make the main structural pieces extremely lightweight. They support a fairly heavy mobile radio and may see vibration and handling during transport. PLA may work for indoor or light-duty use, but a closed dark metal enclosure can become surprisingly warm in direct sunlight. PETG or another higher-temperature material is the safer choice for a field box. Assembly Notes The exact electronics behind the panel can be customized fairly easily. The printed structure is the important part of this upload. My general assembly order was: Test-fit all printed pieces inside the ammo can. Test-fit the FT-1900 in its printed support. Install the cooling fans. Install the speaker, switches, connectors, fuse holders, and controls in the front panel. Wire and bench-test the radio and accessories before final installation. Install the internal divider/storage panel. Mount the radio and front assembly. Route wiring so it cannot enter either fan. Verify fuse sizing and polarity. Test the radio at full transmit power while monitoring temperature and airflow. Only after everything works correctly, secure the wiring and finish the installation. I strongly recommend doing a complete bench test before bolting everything permanently into the can. Modifying the Design There is no reason this concept has to remain FT-1900-specific. The radio cradle/mount is the portion most likely to require redesign for another mobile radio. The general front-panel and divided-storage concept could be adapted for: Other Yaesu mobile radios Icom VHF/UHF radios Kenwood mobile radios GMRS mobiles Packet/APRS stations Portable repeater controllers Digital-mode field stations There is also enough room in the concept to experiment with things such as: USB power Battery monitoring GPS Bluetooth audio Raspberry Pi or mini-computer interfaces Additional data interfaces Other field-radio accessories