Replacement Case for USR/3Com External Modem

Replacement case designed for the USRobotics (previously 3Com) Sportster external modem.
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updated July 20, 2024

Description

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After decades of storage, my original case was very brittle and breaking apart. So I designed this case to fit the original Model 0459 circuit board while also making it a bit more modern and sleek.

In order for the original board to fit, two large capacitors near the volume knob need to reoriented (see pic) which will require some minor soldering skills.

I used sections of clear PETG filament to act as light pipes from the board's LEDs to the top surface. The case halves attach with recessed clips in the rear and (2) M3×6 screws (inserts are M3×6×5) in the front.

This case fits the original volume knob and power rocker, but I've included models for those as well since they're also susceptible to being brittle. If you replace the volume rocker, be sure to transfer over the spring and pin from the original.

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The author marked this model as their own original creation.

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