[MLB-WIRELESS] MelbourneWireless Router Project

[Dan Flett]

Hi all,

I've been jotting down my thoughts on the hardware and software needed
for a prefabricated community wireless router box.  I've set up a
project page here:

http://wiki.freenetworks.org/index.cgi/FreeNetRouterProject

I chose the FreeNetworks wiki because I believe something like this is
universally interesting.  I'm going to chat to people from other
wireless and FreeNet groups around the world to try to get them
interested.

A project like the one above needs to be localised though.  We need a
page one the Melbourne Wireless Wiki that has some local specifications
for hardware and software - each wireless group is going to do routing
and authorisation differently, and hardware needs to be adapted to local
climate conditions.  I haven't set up such a page yet, and I'm about to
go on holidays for 2 weeks.  So have a read of the page above and please
contribute your thoughts and criticisms - and create the MW companion
page if you've got any locally relevant ideas.

I'm building a box at the moment with the aim of making it somewhat
mass-producible (it could be sold in kit form).  I've chosen the
following hardware:

Router:
Linksys WRT54GS
Cost: $150 in bulk buys.
I am removing the PCB-mount RP-TNC connector with a coax crimped to it
from the circuit board and mounting directly though a hole in the
enclosure.  This reduces cost by not needing a separate pigtail to get
the connector outside.  The WRT54GS' Internet (or WAN) Ethernet port
will be directly connected to the AP.  Various software can be installed
on the box - especially if you use OpenWRT firmware.  I would recommend
selling these with OpenWRT installed as Sveasoft is pretty useless for
the way I want to use the WRT54GS.  We would need a quick-and-easy way
to configure the various software apps for use on the Melbourne Wireless
network.  The development of such an interface for the MW network would
be an ongoing project unto itself.

AP:
200mW Senao 2611-CB3+Deluxe
Cost: Approx $160 from various sources.
The Senao AP comes with a MMCX - RP-TNC pigtail internal to it's plastic
box.  I will use this pigtail and mount the RP-TNC through wall of the
enclosure.

There is one slight problem with using a WRT54G(S) with a Senao AP -
they both default to IP address 192.168.1.1 (!!!).  This is not such a
huge problem when you plug the AP into the WRT54GS' Internet port
because it is unconfigured when you set the WRT54GS to factory defaults.
A custom-compiled firmware for the WRT54GS could set default IP address
to a different value.

802.11a/b AP's prices seem to be dropping through the floor at the
moment.  I wonder what's on the horizon.

Enclosure:
Hammond diecast-aluminium watertight box, flanged lid
http://www.hammondmfg.com/dwgw_FL.htm
Model# 1590WFFL
Approx $38 (for 1, cheaper in bulk) from Supplytronics, Rowville, VIC
Other distributors are out there...
I'm drilling holes in the flanged bits for two 1/4"-thread U-bolts from
Radio Parts.  I am using a metal case to allow possible heatsinking of
the AP and Routers' heat-producing components to the air outside the
enclosure.  I am mounting the AP and Router on nylon stand-offs "upside
down" with their components facing the outside wall of the enclosure.

Cable:
25 metres of General Cable outdoor 10-pair - connected directly into box
via a cable gland
http://www.generalcable.co.nz/australia/Products/Communications/Undergro
und_Telephone/5.1.5.2.3.1.pdf
Model# E501
Approx $1.80 per metre from Ideal Electrical Suppliers
I know that 10-pair isn't rated for 100mbps Ethernet.  However, I have
tested 100mbps Ethernet over 50m of 10-pair and it works.  The other
pairs in the cable will be used for the AP and Routers' reset buttons,
separate power feeds to the AP and Router, and possibly a status LED
from the Router.  The aim is to be able to use the AP and Router's own
manufacturer-supplied power-packs, to reduce cost.

Sunshade:
A jacket made from corrugated plastic - as suggested by Tim Hogard.  I
will make a prototype from cardboard and see how strong it is.  I will
fold a sheet of it - wider than the enclosure - over the top of the
enclosure and leave the sides open.  The sunshade will also help to make
the enclosure more waterproof and keep rain off the RF connectors
underneath.

That's basically it.

Tell me what you think!

Cheers,

Dan

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