Outdoor Router Cabinet

I needed to put my router outside because I am sharing my internet with my neighbor. While I originally was going towards a waterproof cabinet, because of high temperatures inside the box I had to add a fan that exhausts at the top.  To protect it I mounted it underneath an overhang.

FYI: The instruction photos may be a little haphazard.  This is because I decided to do an instructable after I had already finished the project.  So I tore as much down as I felt comfortable and started from there.

Here are the parts you'll need:

* Orbit Weather Resistant Sprinkler Timer Cabinet ~$30
* ASUS RT-N66U ~$150 (any router that will fit in the box and has external antennas will do, but this router is pretty awesome.)
* 3 X 8"/20cm Male to Female RP-SMA Extension Cable ~$5.50 x 3 = $16.50
* Coolerguys 120x25mm Rear Exhaust Blower Fan 5 Volt with USB Connector ~$15
* Velcro Reusable Straps ~$10 (these are just generally useful)
* Velcro Brand Sticky Back Tape 3/4"X3-1/2" 4/Pkg-Black  ~$5
* Short surge protector.  I found one in the dollar store that had 3 outlets and a 1 foot cord.
* 3/4 inch nm clamp ~$1
* 1/2 inch nm clamp ~$.70
* 2 - 1 1/4 inch #16 nails

Tools I used:
* Drill with 1/4" bit
* Phillips screwdriver
* 1 1/4" hole saw bit
* Needle nose pliers
* Dremmel
* File
* Hammer

This will be the easiest step.

I'm leaving how to get power to the box up to you. I happened to have a nice outside light I wasn't using so I drew power from there.  You can see it in the bottom left of the picture.

This will get in our way when we install the fan. Make sure that the bottom is pretty flat.  In the picture it was underneath the bottom of the fan.

I used a dremmel for this, but you can cut it by any means. Line up the exhaust portion of the fan at the top of the box. Take care that you aren't going to be cutting the mounting plate screw posts. Also give yourself enough room to not cut into the bottom of the box. You'll also need to cut in the back part so the fan will be underneath the plate. I think it would be best to cut it from the outside. I cut it after it was mounted so I had to do it from the inside which made a pretty ugly cut.

WARNING: putting the fan at the top made it no longer weather proof. So if you would like to keep it weather proof I would look at the possibility of mounting it on the left orright and build something that will protect the exhaust from rain. Since my box is under an overhang I wasn't too worried.

Use the 1 1/4" hole bit to cut a hole in between the top door hinges. Be careful to not cut the hinge.

This one could be optional. I had a power brick on my router that likes to stick straight out.This doesn't work so well in the case. I had a big mess of wires already so at the time I didn't want to run my cord through the existing holes. Plus the plug didn't fit through them. If I was to do it again I would look at buying a short extension cord and see if I can stuff the power brick under the mounting plate.

Use the 1/4" bit to drill the holes at the bottom these should be evenly spaced and be in front of the mounting plate.

This is to keep the cords from getting cut.  Also seals up the holes. You can see the metal pieces on the left and right.

Insert the fan into the cut out and using nails nail it into place. My hammer was only able to fit in two places so I only got two nails in, but it worked fine. Be careful to not break the exhaust fan. They don't have to be super tight as the mounting plate will keep it from vibrating.

If you are going to be mounting this on the wall then screw it in with the provided screws.

Bring your cable in and let it hang outside the box. Use Velcro ties so it can fit neatly next to the fan with enough extra length to be able to plug it in the router.

You can see mine pulled into the right hole.

Take 3 of the velcro straps and place them together.

Take the strap and wrap it around the plate through the cut out.  attach it together so it will hold on while you are screwing it in.

Insert the male ends through the drilled holes and screw them in.  Use a pair of needle nose pliers to tighten them up.

Put the surge protector cable through the hole and plug it in.

Cut out small squares of velcro and attach them to the feet of the router.

Pull off the sticky velcro backing.  Attach the router to the plate and secure with the strap.

Screw in the antenna extension cables into their closest spots on the router.

Hopefully you have a USB slot otherwise you may want to look for a USB ac adapter.

Put the router power cord in the same hole as the surge protector and plug it in the router.  You can plug the other end into the surge protector.

I have an OB100 that I use for my home telephone.  I attached it to the door using velcro strips and attached the other end to the main phone box for my home.   I use the velcro ties to clean up the network cable to the router.

Attach the antennas that came with the router to the outside posts. 

Use velcro strips to attach the surge protector to the top of the case.  You can see in the picture I put it in front of the fan.

Now it should be ready to go.  It's a fairly clean way of building a housing for your router.