Raspberry Pi Travel Server – Built for the Apache 1800 Case 💼🍓

Turn the Harbor Freight Apache 1800 case into a portable, rugged offline server with this custom 3D printable mount system for Raspberry Pi and Orange Pi 5 Plus boards. Designed for Jellyfin, file servers, and travel projects, this setup lets you safely house your Pi without cutting into the case—preserving its waterproof seal.

The print includes a front plate for power and ports, a back plate to securely mount your Pi, and a sliding keyboard tray that fits in the lid. It supports full-size Raspberry Pi boards, Pi Zero, and even the Orange Pi 5 Plus with the included alternate tray.

There's no built-in cooling, but it runs cool enough in testing—even when used as a media server for road trips. Power is routed to the front plate via USB-C, making it easy to connect any external power bank or USB outlet. There’s also a built-in switch on the front plate, ready for optional functions like screen backlight control.

Why Use the Raspberry Pi Travel Server Mount?

✅ Compatible with Pi 4, Pi Zero, and Orange Pi 5 Plus
✅ No Case Modding Needed – Keeps the case watertight and rugged
✅ Front-Accessible Ports – 2× USB-A, Ethernet, USB-C power
✅ Keyboard Tray in Lid – Clean, space-saving design
✅ SSD Room & Expandability – May fit an SSD depending on layout
✅ Simple, Sturdy Construction – All mounting hardware included (2.5mm and 3mm)
✅ Portable Media Powerhouse – Built for offline Jellyfin streaming

How to Use It:

1️⃣ Print all parts in PLA or other sturdy filament.
2️⃣ Mount your Pi (or Orange Pi 5+) using 2.5mm hardware.
3️⃣ Mount the ports to the front plate using 3mm hardware (USB, Ethernet, power, optional switch).
4️⃣ Slide the keyboard tray into the lid.
5️⃣ Plug in power via the front USB-C and load up your media server.
6️⃣ Enjoy a portable, private streaming experience for you and your family! 🎬🚗

Example Uses – What I Run on My Server:

💾 Jellyfin for offline media streaming (great for road trips!)
🧠 A small, local chatbot – slow, but it works!
📚 A collection of PDF survival manuals and reference files for offline access

This setup turns a rugged case and a Pi into a powerful offline toolkit for entertainment, reference, and tinkering—wherever you go.

Assembly Instructions 

1. Print the appropriate Pi tray for your board.
   • Two tray options are provided:
     • One tray fits Raspberry Pi 4 or Raspberry Pi Zero
     • The other tray fits the Orange Pi 5+
2. Print the faceplate.
   • The print will pause near the top to allow insertion of embedded hex nuts.
   • If you prefer not to use embedded nuts, simply resume the print and use heat-set inserts instead.
3. Verify the Pi is fully functional and configured for use as a server before installation.
4. Mount the Pi to the tray.
5. Mount the USB ports to the faceplate.
6. Determine the best cable routing from the faceplate to the Pi before final assembly.
7. Attach the Pi tray to the faceplate, with the screen positioned between them.
8. Slide the assembled unit into the case.
9. Secure (or don’t secure) the faceplate to the case.
   • If you want the unit to be removable later, you may choose not to permanently secure it.
   • The only current mounting option is adding a few small drops of glue around the faceplate.
   • I chose not to secure mine, and it has held up well during travel.

🔗 Hardware Links (Affiliate):

💼 Apache 1800 Waterproof Case – Harbor Freight
🍓 Raspberry Pi 4 Model B – Amazon
🧡 Orange Pi 5 Plus – Amazon

🖥️ Display - Amazon
🔌 USB-C Panel Mount Port – Amazon
🔌 Ethernet Panel Mount – Amazon
🔌 USB-A Panel Mount – Amazon
🔌 Screen Power Cable - Amazon

🔌 HDMI Cable - Amazon
🧰 M2.5 and M3 Screw Assortment – Amazon

If you found this model interesting or useful, consider supporting my work! Every design takes time, testing, and a lot of coffee to bring to life. If you’d like to help fuel future projects, you can buy me a coffee here. Thanks for your support!