01
Verify the Brain Boots
Prove the Pi 5 is healthy before it disappears into the chassis.
- Inspect the Pi for physical and connector damage.
- Attach active cooling temporarily.
- Boot from a known-good microSD image.
- Confirm HDMI, keyboard, mouse, Ethernet, Wi-Fi, and USB all respond.
“Seat the brain before you build the body.”
Pass — Pi boots, outputs video, accepts input, reaches the network, holds a stable temperature.
02
Prepare NVMe Storage
Make NVMe the main boot and data path.
- Install the M.2 HAT+ or the selected integrated carrier.
- Mount the 1TB NVMe SSD securely.
- Flash Raspberry Pi OS 64-bit (or chosen base) to NVMe.
- Keep the microSD as rescue media only.
“NVMe is the spine. microSD is only the parachute.”
Pass — System boots from NVMe and exposes the expected capacity.
03
Partition + Encrypt Data Layout
Create a clean operational storage model that contains dirty data.
- Create the OS root.
- Create an encrypted captures volume.
- Create an encrypted case-data volume.
- Create labs and wordlist volumes.
- Create a scratch volume for disposable PCAPs, extractions, and caches.
/ 80–120GB OS root
/opt/tools 100GB tool workspace
/data/captures Encrypted packet captures
/data/cases Encrypted case + engagement records
/data/labs Docker-compose labs + local ranges
/data/wordlists Compressed wordlists + indexes
/data/reports Notes, screenshots, exports, reports
“Separate evidence, labs, reports, and scratch. Dirty data stays contained.”
Pass — Encrypted volumes mount only after authentication; every path is clearly labeled.
04
Install Cooling + Chassis Base
Build a stable thermal and mechanical foundation.
- Install the active cooler or case-integrated cooling.
- Mount the Pi + NVMe carrier on standoffs.
- Verify the airflow path is clear of cables and panels.
- Secure the fan cable away from hinge movement.
“Heat kills field gear. Airflow is a component.”
Pass — Pi idles and loads within thermal limits with no cable interference.
05
Build Split Power Rails
Stop displays, radios, hubs, and storage from fighting over power.
- Create Rail A for the Pi 5 + NVMe.
- Create Rail B for the two displays.
- Create Rail C for the USB hub, radios, GPS, OLED, and Ethernet accessories.
- Add fusing or protection where practical.
- Label every rail physically and in the UI.
“One weak rail makes the whole deck unreliable. Split the load.”
Pass — Deck stays stable with both displays, NVMe, keyboard, Ethernet, and radios attached.
06
Install Hardware Switch Panel
Give the operator physical control over major subsystems.
- Install four low-profile toggles.
- Switch 1 → display rail.
- Switch 2 → USB hub / accessory rail.
- Switch 3 → fan override.
- Switch 4 → auxiliary module rail.
“Software profiles are nice. Physical switches are decisive.”
Pass — Each switch visibly and electrically controls its assigned subsystem.
07
Mount Dual Displays
Create a two-screen clamshell workstation.
- Mount the touchscreen as the left / lower CONTROL display.
- Mount the HDMI panel as the right / upper WORK display.
- Use short right-angle HDMI adapters where needed.
- Route the USB touch cable separately from power.
- Test both displays at boot and after wake/resume.
“Left screen controls the deck. Right screen does the work.”
Pass — Both screens initialize reliably and hold correct orientation.
08
Install Input System
Support both mobile and serious typing workflows.
- Pair the mini wireless keyboard + trackpad.
- Add a dock / stow slot for the 60% mechanical board.
- Add a mouse, trackball, or pointer if desired.
- Map hotkeys: mode switch, screenshot, terminal, capture start/stop.
“The mini keyboard is for movement. The mechanical board is for work.”
Pass — All input devices work without interfering with Wi-Fi or USB storage.
09
Install Network Interfaces
Create separate management, capture, and wireless lanes.
- Onboard Ethernet → management / stable uplink.
- USB gigabit Ethernet → capture / isolated lab lane.
- Wi-Fi adapter 1 → authorized monitor-mode auditing.
- Wi-Fi adapter 2 → connectivity / AP / comparison.
- Physically label every interface on the chassis.
“Three network lanes: manage, capture, radio.”
Pass — Each interface has a stable name, a visible role, and a clear profile assignment.
10
Install OLED Status Display
Expose essential state without opening a dashboard.
- Wire the OLED over I2C / the selected display bus.
- Show host, mode, primary IP, VPN, CPU temp, battery, free storage, capture state.
- Use low-refresh logic to save power.
“Status belongs on hardware, not buried in a menu.”
Pass — OLED updates reliably and stays readable in field lighting.
11
Install GPS + RTC
Improve field metadata and offline time accuracy.
- Install the RTC with a coin cell or backup power.
- Install the GPS module where the antenna has sky exposure.
- Verify time persists after power loss.
- Keep GPS metadata optional and operator-controlled.
“Bad timestamps ruin evidence. Fix time before field work.”
Pass — Offline boot has correct time; GPS status is visible only when enabled.
12
Install Hardware Auth Bay
Make strong authentication part of the physical deck.
- Cut a recessed slot for the YubiKey / Nitrokey.
- Configure SSH with hardware-backed keys.
- Configure Git signing if needed.
- Wire up the password-vault unlock workflow if needed.
“The key is part of the machine. No key, no operator state.”
Pass — Admin and sensitive workflows require the token where appropriate.
13
Build the OS Profile Layer
Run multiple operational postures from one deck.
- Create a base OS: stable desktop, terminal, networking, update path.
- Create mode profiles for Blue, Red, Forensics, Field, and Lab Beast.
- Each profile powers a different hardware subset and exposes different status fields.
“Five postures. One deck. Different power, tools, and stance.”
Pass — Operator can boot or switch into the right profile without reconfiguration chaos.
14
Install Tooling by Category
Build a structured tool environment, not a junk drawer.
- Install by role. Every tool needs a mode and a purpose.
- Keep categories isolated and documented.
- Keep tool directories recoverable.
Base Terminal
tmux, shell config, fzf, ripgrep, jq, yq, curl, wget, git, Python, Go, Rust
Blue Team
tcpdump, tshark, Wireshark, Zeek, Suricata, osquery, Sigma/YARA, log parsers, IR templates
Red Team (authorized)
Nmap, range scanners, web proxy/test tools, dir enum, nuclei (owned assets), lab-only validation
Wireless (authorized)
Kismet, Wireshark, aircrack-ng suite, adapter diagnostics, GPS survey logging where permitted
Forensics
hash tools, Sleuth Kit, metadata tools, binwalk, bulk extractors, timeline utils, read-only mount helpers
Reporting
Markdown editor, screenshot util, diagramming, Pandoc, PDF export, report templates
“Install by role, not by hype. Every tool needs a mode and a purpose.”
Pass — Tool directories are organized, documented, and recoverable.
15
Create Recovery + Maintenance Plan
Make the deck field-repairable and hard to brick.
- Create a rescue microSD card.
- Create a labeled backup target.
- Use stable disk IDs, not volatile /dev/sdX names.
- Document the restore procedure in the UI.
- Back up configs, scripts, profile files, and report templates.
“Recovery is not optional. A field deck needs a parachute.”
Pass — Operator can restore from documented media without guessing device names.
16 · OPT
Optional Edge AI Decision
Decide whether AI hardware belongs in this exact deck.
- Default: keep the PCIe path dedicated to NVMe.
- Use AI HAT+ 2 only if local inference beats clean NVMe architecture.
- Alternative: USB accelerator, networked workstation, or remote inference box.
“AI is optional. NVMe is core. Do not trade the spine for a gimmick.”
Pass — Operator understands and accepts the tradeoff before seating the optional module.