I Built My Own Extreme Duty Meshcore Node
▶ Watch on YouTube Subscribe to Dude Tested
In this video
- 0:00 Intro
- 0:29 The benchmark: Mesh Radio Rugged US915
- 1:17 The case: PolyCase EX52
- 2:15 End cap hardware
- 3:08 My mess-ups
- 4:21 It's okay to build unfinished
- 5:11 Why build instead of buy
- 5:52 What's wrong inside
- 7:28 The version two plan
- 8:14 Back together + power test
- 9:06 Does it work? Mesh trace test
- 10:06 What's next
About this video
This DIY Meshtastic / MeshCore companion node isn't finished, and I'm showing it to you anyway.
It's version one (V1) - a RAK4630 in a PolyCase EX52 aluminum enclosure, built to chase the Mesh Radio Rugged US915 I've carried every day for a year. It works. It also has a shaved antenna cover, scratched end caps, a battery double-side-taped to the case, and a lot of lessons.
I'll walk you through everything I got wrong, how it held up on a real mesh trace test around Chicagoland, and what gets fixed in the next version. Plus a little plot twist with the Bluetooth antenna.
That's what Dude Tested is about. We make things, break things, and build them back better, out in the open, mess-ups and all. Perfect is the enemy of the good. If you've been sitting on a build idea, start your version one, and show me.
🔔 Subscribe to follow this node from rough draft to finished. I am trying for 100k by Sept 15, 2027
⏱️ CHAPTERS
🔧 PARTS I USED
These links show exactly what's in V1. *They are not recommendations yet.* Some of these parts caused the problems you'll see in the video, and parts may change as the build evolves. The parts below, ordered in pairs plus the case, ran well over $180, and that's before the battery and cable.
Some links below are affiliate links. As an Amazon Associate I earn from qualifying purchases, at no extra cost to you.
- LoRa antenna: TE Connectivity Linx 916 MHz whip, SMA (ANT-916-CW-QW-SMA)
digikey.com/en/products/detail/te-connecti…
- LoRa pigtail: Amphenol RF MHF1 to SMA, 5.9" (095-902-585-150)
digikey.com/en/products/detail/amphenol-rf…
- Bluetooth antenna: TE Connectivity Linx 2.4 GHz dome, U.FL (ANT-2.4-WRT-MON-UFL)
digikey.com/en/products/detail/te-connecti…
- Power switch: APEM push button, SPST (IPR1SAD2)
digikey.com/en/products/result?keywords=67…
- Enclosure: PolyCase EX52
- Board: RAKwireless RAK4630
- Battery: 3 Ah LiPo
- USB-C cable: IP67 USB-C male to female panel mount
📡 THE BENCHMARK
Mesh Radio Rugged US915 (currently sold out)
etsy.com/shop/MeshHardware
etsy.com/listing/1720431272/
MeshRadio Power Distribution Board, the one I'd love to use (also sold out)
etsy.com/listing/1739267779/meshradio-powe…
🛠️ WHAT'S NEXT
A longer shelf to hold the battery and RAK board, a better antenna fit, and a new push button switch. Maybe moved to the bottom, like some of you suggested.
💬 Got a better part, a smarter layout, or a fix? Drop it in the comments. Solutions are always welcome. Check the comments first, because your question might already be answered.
