Overview

This project integrates a Raspberry Pi 5, 10.1" display, power bank, cooling system, and peripherals into a compact briefcase-style enclosure. The design emphasizes modularity, serviceability, and clean cable management. This is the successor to the Raspberry Pi Apache 2800 Pentesting Rig.

Raspberry Pi Apache 2800 Pentesting Rig

Key design features:

• Heat-set inserts for long-term durability

• Magnetic panel mounting for tool-free access

• Modular base and panel construction

• Internal cable routing for a clean, organized layout

The internal frame is friction-fit into the briefcase, so no permanent modification or mounting to the case is required. Depending on the case used, minor cosmetic wear may occur over time.

Overall Dimensions:

16.25 in × 11.325 in × 2 in

Note: This project is intended for educational and laboratory use. Ensure all activities comply with applicable laws and network authorization requirements.

Materials

Printed Parts

Base Components

• base_battery

• base_keyboard_left

• base_keyboard_

• base_pi_and_ports

• base_screen_left

• base_screen_right

• connector (x11)

Panel Components

• panel_battery

• panel_keyboard_half (x2)

• panel_pi

• panel_screen_left

Other

• pi_cover

• 40mm fan cover grills (x2)

40mm fan cover grills (x2)

• 40mm fan cover pins (x8)

40mm fan cover pins (x8)

Hardware

• 0.187 in. L X .5 in. W Disc Magnets (x14)

Product used

• Washers to go in the panels (x14)

• Slot size: 0.406" diameter x 0.05" depth

• M3 heat inserts (x24)

Product used

• M3-0.5 x 4mm screws (x24)

Product used

Electronics

• Raspberry Pi 5 (NVMe HAT optional)

• 40mm fans (x2)

Product used

• 10.1" display

Product used

• USB Hub

Product used

• Micro HDMI Male to HDMI Female

Product used

• Bluetooth keyboard

Product used

• Bluetooth mouse

Product used

• 65W USB-C power bank

Requirements:

• 65W recommended

• Must physically fit battery compartment

• Capable of powering Raspberry Pi 5 and display simultaneously

Note: The original build used a Baseus BS-30KP365 power bank. This model has since been recalled and is not recommended. Select a current-production alternative meeting the specifications above.

• HDMI cable

• Pi power cable

• Display power cable

Miscellaneous

• Pick apart foam

Tools

• Soldering iron (for heat-set inserts)

• Adhesive (E6000 or epoxy)

• Screw or hex driver (for M3 screws)

Assembly Instructions

1. Install Heat-Set Inserts

Install all M3 heat inserts into the designated holes on all base_* components.

• Use a soldering iron with a flat tip.

• Ensure inserts are flush and perpendicular.

Allow parts to cool fully before handling.

2. Install Magnets (Base Pieces)

Glue disc magnets into the hexagonal magnet recesses on all base_* parts.

Adhesive used: E6000 (or equivalent flexible epoxy).

Important: Let fully cure before proceeding.

3. Install Washers (Panel Pieces)

Glue washers into the circular recesses on the back of all panel_* parts.

Adhesive used: E6000 (or equivalent flexible epoxy).

These act as magnetic targets for the base magnets.

• Ensure washers sit fully flush in the recess.

• Allow adhesive to fully cure.

4. Assemble the Base Structure

Place all base_* components into the briefcase.

• Use the connector pieces to join the base sections together.

• Each connector uses two M3 screws.

• Tighten until snug.

Once complete, the base should form a rigid internal framework.

5. Install Electronics

Raspberry Pi + Cooling

• Place the HDMI adapter in the upper-right slot of base_pi_and_ports.

• Place the USB hub into the adjacent right-side slot.

• Position the Raspberry Pi inside the recessed area of base_pi_and_ports. Note: due to cable tolerances, the Pi may not sit perfectly in the recess once fully wired. This does not affect function; cable tension helps retain the board securely.

• Connect:

• Pi power cable

• Both HDMI cables

• Route:

• Display HDMI cable toward the display section

• Display power cable toward the battery compartment

• Install both 40mm fans into pi_cover.

• Connect fans to the Raspberry Pi.

• Secure pi_cover using M3 screws.

• Attach fan grills using fan pins.

Screen

• Place the 10.1" display into the screen base sections. Three magnets will hold it in place.

• Plug in HDMI and power cables.

• Most excess cable length can be routed beneath the screen cavity.

Power

The power bank slides into the battery compartment.

• panel_pi may need to be temporarily removed during cable installation.

• The Raspberry Pi and display are powered directly from the power bank.

• Currently, when fully powering down the system, cables must be unplugged manually.

Verify clearances if using an alternative power bank model.

6. Final Assembly

Once all electronics are secured:

• Place all panel_* pieces onto the base.

• Magnets should align with washers.

• Verify all panels sit flush.

• Panels may need to be pressed into place if the briefcase fit is tight.

7. Peripheral Storage

Place pick-apart foam beneath the keyboard section to store:

• Mouse

• Cables

• Adapters

• USB tools

This keeps accessories secure during transport.

Recommended Print Settings

• Material: PLA / PETG recommended

• Infill: 15–25%

• Walls: 3–4 perimeters

• Supports: Parts were designed to minimize needed supports, but some will still require them

• Layer Height: 0.2mm

• Print panels with the top face on the build plate to get a nice finish.

Raspberry Pi Briefcase Pentesting Rig

0.2mm layer, 2 walls, 15% infill