I made these covers for the controller board because the pcb sitting 4mm above the threaded rod just seemed like an accident waiting to happen. Also, the usb connection seemed a bit slack so I wanted a widget to tie the cable to.

The covers can be made from just about any card, wood, plastic etc. I made the base from 3mm MDF and the top from clear acrylic. The top has holes to allow acces to the jumpers and reset button.

Get making:
Load the .svg file into your drawing program of choice (I ❤ Inkscape)
Export to your cutter of choice (laser, cnc, plasma etc.)

To mount your covers on the board and on the machine you will need some longer (25mm) bolts. You will also need some spacers (8mm) between the top cover and the Melzi board.
I made spacers from cable insulation, nothing fancy. The top cover should sit over terminals and line up with the M3 bolt holes. Next, fit the base cover over the bolts and then attach back to the brackets on the threaded rods.

Attach the usb cable and fasten with tie wrap or similar.
Your Rep Rap should now be safer and more handsome too.

Share & Enjoy!