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Please Meet Stanley

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N2MH's picture
Please Meet Stanley

Stanley is a Mesh Go-Kit that I put together at the end of the summer. When deployed, Stanley consists of a 2 GHz WiFi client, and a 5 GHz node capable of being a tunnel client. Both units are NanoStation Loco's. When deployed, Stanley looks like this:

Stanley is built into a 3 piece Stanley rolling toolbox. The PVC arms are on heavy duty hinges which fold up from a plywood base which also houses the various electronics and power circuity components. Keeping the arms from swaying in the breeze is a piece of 1x2 wood with u-bolts around the arms at the top. Looking inside, here is what is on the plywood base:

Inside, there is a 12V DC / 7 AH battery, a fused power distribution module, a GS-108e vlan switch, and a PoE Texas multiport ethernet power injector. On the inside of the 2x4 on the right is a small digital voltmeter used to keep tabs on the battery voltage.

Inside the top cover of Stanley is a surprise:

The surprise is a 2 port USB charger for cell phones. (See the left compartment.)

The Stanley rolling toolbox has 3 compartments:
- a top compartment which houses all the active parts of Stanley
- a middle section which has many small compartments, suitable for storing hardware, etc.
- a bottom section which is used for storing bulkier things such as cables, a battery charger, and a VoIP phone.

The Grandstream 1625 phone plugs directly into the POE strip and gets its power from there.

Built into the base of the phone is a reverse POE injector which pulls 12V from the ethernet cable and then runs it through a small 5V switching regulator to power the 5V phone.

When it's time to go back home, everything folds neatly back into the top compartment ready for his next adventure.

Stanley has room on his POE strip for another node. This node will be powered by the battery and will talk DTD to Stanley's normal 5 GHz node.

I hope you liked meeting Stanley. He is very friendly!


Would it be possible to ask for (request) a somewhat detailed parts list for your Stanley?  Reason for asking is that I would like to build one for use in a CERT group I belong to.  The use in that group would be both 'show and tell' and, more hopefully, an inspiration for a few others in the group to build other 'Stanleys' for testing and for use in activations.
Thank you,
James Good kd5vxh
N2MH's picture
Parts List

James, give me a couple of days to put the list together. Many of the pieces came from the Junque Box. So, I have to go back and get the original part numbers and vendors for those items.


If you can find my email
If you can find my email address in the register here, that is the one I use most often and would be most likely to see and read.
Thank you,
James kd5vxh
W2TTT's picture
Please Meet Stanley

Nicely done!  I like your approach to field operation.
I did something similar, but with the objective of providing a test/demo/educational platform that could also provide utility as a traditional go kit.  I packed a bunch of stuff on 2.4 and 5 GHz into a small Dewalt case.  It does lack intrrnal power, but does feature a VoIP phone, a switch, an AP, a Zumspot/Pi3, another Pi3, and 12 and 5 Volt power disstribution.  Power and the laptop are my next projects.  The power is in a prior preferred box format, so that may wait... TBD
I'll share what I have soon once I take pictures.
Gordon Beattie, W2TTT


N2MH's picture
Bill of Materials

Here's the Bill of Materials as best as I can put it together

Stanley 3-piece rolling tool box
Stanley p/n STST18614
Lowes sku 595246
Home Depot has a similar unit but its not quite the same.

20190506 - See posting below about availability of this rolling tool box at Lowes.

Ubiquiti 2 GHz and 5 GHz NanoStation Loco
Available from many vendors
Software for the 5 GHz Node can be found on this website

NetGear GS108e VLAN ethernet switch
Available from many vendors

Fused power distribution module
Blue Sea Systems p/n 5025
West Marine sku 3733482

2-Port USB Charger Outlet
West Marine sku 15830490
Quicksilver also sells something similar

Digital VoltMeter
Quicksilver SKU cvolt-green!/Digital-LED-Voltmeter-Green/p/51010084/category=11543079

12V @ 7AH
Available from many vendors

POE Injector
PoE Texas WT-GPOE-4B
Available on Amazon

Mast Tee hinges
Everbuilt Model # 15291
Home Depot SKU #339253
Similar ones can be found at Lowes and other hardware outlets

Mast Material
1 " and 1 1/4" PVC schedule 40 pipe - cut to size
Available at many stores.
The 1 1/4 " pipe slides over the 1" pipe and extends it another foot or so. 1/4x20 bolts keep the extension pieces in place.
Both Ubiquiti devices mount to the 1 1/4" sections with hose clamps. I don't trust the cable ties supplied with the devices.

DC power cables for ethernet switch and poe injector. Also used on phone. Includes 2.1mm connector.
Tensility CA-2185
Digi-Key p/n CP-2185-ND

5V Switching Regulator used to power phone
Digi-Key p/n 811-2692-ND
OKI also makes a similar unit with leads bent at right angles to this part.

Grandstream GXP1625
Available from many stores.

Miscellaneous Material - use as needed and/or cut to size
3/4" plywood - plywood base
1x4 lumber - partitions on plywood base and mast separator
2x4 lumber - mounting area for masts
1/4x20 screws, nuts, washers, lockwashers
Wing nuts
Ubolts for mast separator
Hose clamps to attach Ubiquiti equipment to mast material
PowerPoles to connect usb outlet, charger or other things
Faston clips for battery
Inline fuse for battery
Wood screws for partitions, hinges, et. al.
Cat5 cable and heads as needed
Battery charger - I used an old Radio Shack 12V power supply from the Junque Box (transformer type!)

Note that the whole affair is built on the 3/4" base and is removable from the rolling tool box. It is completely self-contained
Also note that the top compartment of the rolling tool box can be removed and placed on a table top, desk, etc. for indoor use.

N2MH's picture
5V Power for Phone

I was able to sneak the 5V Switching Regulator used to power the phone into the base of the phone along with a reverse connected POE injector.

KI7ODK's picture
POE for GXP1625

Sorry to "resurrect" this thread, but I was just wondering why you used a reverse POE injector to power the GXP1625 instead of powering it directly via POE?


kc8ufv's picture
I would suggest that as the
I would suggest that as the entire setup is battery powered, it's for efficiency. Internally, when fed with 48V POE, these types of phones will normally step the voltage down to 5V. Keeping the phone closer to the battery will help reduce the loss as well, and no need to deal with the complication and efficiency losses of an extra power conversion. 
N2MH's picture
POE Choice

I used a POE "extractor" to pull 12 volts from the battery and step it down to 5 volts to locally power the phone. If you look closely in the base of the phone, you can see the OKI 5V switching regulator that I snuck in there. And, it didn't take any extra room, anywhere.

Stepping the 12 volts from the battery up to 802.3af would involve a lot more complexity. For starters, I'd have to step up the 12 V to 48 volts and then condition it with a POE controller and feed it out to the phone. Not only would this take up more physical space in the go-kit, it would possibly be less efficient power-wise. Since the whole go-kit is powered by a single battery, you have to keep power losses to a minimum.

Also, keeping all POE at 12 volts keeps all power standard in two ways:
1. This POE style is the same as for the nodes. Thus, a standard, muti-port POE injector works nicely for all devices.
2. There is no possibility of mixing up the two variants of POE: 802.3af and passive POE. What's important about this point is that besides being different voltages, they are different polarities. Mixing them up in the field could be disastrous.

Simplicity Rules!

73, Mark, N2MH

KI7ODK's picture
POE Choice
That makes sense, thank you for the explanation!
N2MH's picture
Hello Crafty, Goodbye Stanley

On my recent travels to Lowes, I no longer see this black and yellow rolling tool box. I do see what looks to be the same item in black and red under the Craftsman logo. Indeed, the last part of the model number is the same. (Black and Decker owns the Stanley brand and now own the Craftsman brand, formerly owned by Sears.) Enter the name "Crafty".

So, please modify the Bill of Materials accordingly:

CRAFTSMAN DIY 19-in Red Plastic Wheeled Lockable Tool Box
Craftsman p/n CMST18614
Lowes Item Number 1048640

W2TTT's picture
"Crafty" is a better match!

Noted the evolution of Stanley to Crafty and couldn't help but note that the black and red will better match your Promaster City.   :-)
One day, I need to get with you and your respective RED Promaster City and Promaster 3500 159 WB EXT vehicles and put them side by side and stand there with your Stanley and my Walter go kits!  The photos would be both humorous and instructive!

W2TTT's picture
Walter's Chariot Promaster 3500 159 WB EXT

Mark et al,
I will post some photos of one element of Walter later tonight.   It is a large briefcase-sized toolbox from Dewalt and rides on a similar, but larger rolling container that is home right now, while we are in Dallas for a Mary Kay conference.  

In the meantime, here is a photo of Walter's Chariot.
The AREDN Mesh gear is just getting installed as we develop the platform.

File Attachment: 
W2TTT's picture
Walter - aka W2TTT-FIELD
OK, attached is a photo of the W2TTT-FIELD kit. The power, mast supports, cameras, laptop, etc. go in a lower rolling case that is separate. This unit is deployable on its own and can support three dtd nodes. There is a 5 GHz Bullet as a base unit, and a 2 GHz Nanostation as an internal or mast deployable node. There is also a preconfigured VLAN for a third node. The unit also has a Wi-Fi access point and a cellular modem. Inside there is an RPi3 for general use and another running a DMR and YSF Hotspot. The VoIP phone is on two different switches, AL0Y's and my own. Its IP is public for IP dialing. Internally, there is a 12V POE injector, a 4 port USB power adapter and a small RigRunner. This unit can operate closed as power and Ethernet connectors are on the sides. Guess, I will need to trim the photo sizes later...
KL7VK's picture
Nice job Mark. I did the same thing a couple of years ago but added a hAP ac lite and a 100 watt solar panel along with a solar charger for batteries. Since then I have re-purposed my rolling tool box but it can be converted to my "Stanley" quickly.
KM6SLF's picture
Sorry I didn't see this
Sorry I didn't see this thread earlier - Great kit! I put together a kit like that, but with a few key differences:
No phone, but lots of data services
No on-board battery, though designed to be easily powered from an external 12v source
Makita box rather than Stanley :)
It looks like a bit of a rats nest, but that set up incorporates the following devices and services:
4x Raspberry Pi 4Bs running TeamTalk, Citadel, NextCloud, and a PBX server
1x Raspberry Pi (original) running Meshchat
1x AWow Mini PC running WinTak
1x 12v 300W rugged power supply (overspec'd to keep things running cool and to be able to charge or power additional 12v devices)
1x Microtik hAP mesh node
1x Powered USB hub
1x 8 Port Switch

In addition to those digital services, the kit had an AC power cord that could be stored inside the box or pulled through a cable gland on the left side of the box. A 12V source could be plugged into a 12V DC/DC and fed into the power distribution board to power the assembly from a battery or a car cigarette lighter. Ethernet cables for ports 1 & 5 were run through cable glands to the outside of the box on the right side, with waterproof connectors to get internet in and 24V PoE out. The whole kit runs on about 40 Watts.

I started the kit when the pandemic started and finished it back in May of last year. Since then, in collaboration with technical leaders of other area RACES/ARES teams, substantial improvements are in progress. Version 2 of this kit will provide more services than the old kit provided, including Winlink and Wikipedia (representing about 6.3 million articles) but will require fewer devices to do it. It will also incorporate about 400 watts of battery power from a pair of LFP batteries. I'd say the V2 kit is about 80% finished now. I'll post photos and details when it's finished, but here's a teaser


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