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Custom Instrument Housing Examples (Page 1 - Page 2 - Page 3)
 
Instruments that were designed for use above water often need to be used underwater, but the manufacturers do not often offer a housing for them. 

We can design housings that keep the equipment dry, have external controls for operation, and meet the depth requirements of the project. Sometimes, there is no depth requirement, the only need is to keep the equipment protected from rain, snow, humidity, mud, sand, and other debris.

Shown below are examples of designs we have done, with some notes about the requirements and how they were met.

Underwater housing for iLab spectrophotometer (2009)
This 160 foot housing was made for a customer is Perth, Australia, for studies of photosynthetic activity of coral reefs. It uses a sapphire window in the top of the door to minimize distortions to color and quality of the light passing both directions from the internal light source and back to the sensor in the unit.

Photo by Ken Sexton.

Underwater housing for iLab spectrophotometer
Click to enlarge

Mount for Underwater Audio Source (2009)
These mounts were made for large underwater sound sources, allowing them to be precisely positioned on the sea floor. The mounts are adjustable in height, and the extra holes are for securing the unit to the seabed.

Photo Credit: Ken Sexton.

Mount for Underwater Audio Source (2009)
Click to enlarge

Housing for FireWire to Cat5 Converter (2009)
This housing was designed to enclose a converter from FireWire to Cat5 cable, allowing a FireWire-based camera in a previously-built housing to have its useful cable length extended from 3 meters to 90 Meters. A similar converter changes the Cat5 back to FireWire at the other end.

Photo Credit: Ken Sexton.

Housing for FireWire to Cat5 Converter (2009)
Click to enlarge

Deep Laser Housing for Orion (2009)
This deep housing is made of aluminum tubing with double o-ring sealed doors on both ends. It houses a powerful Orion red laser, shining through a cylindrical lens to produce a plane of light. The tube is hard anodized and then powder-coated.

Photo Credit: Ken Sexton.

Deep Laser Housing for Orion (2009)
Click to enlarge

Deep laser housing for Hercules, second version (2009)
Similar in construction to the Orion housing above, this houses the same very large green laser as the one below.

Photo Credit: Ken Sexton.

Deep laser housing for Hercules, second version (2009)
Click to enlarge

Travel Case for Two lasers (2009)
The Storm case shown has room for the two Orion and Hercules laser housings shown above, as well as two pairs of telescoping arms that are used to position the lasers with respect to the camera housings they are attached to.

Photo Credit: Ken Sexton.

Travel Case for Two lasers (2009)
Click to enlarge

Deep Audio Housing for Elephant Seals (2009)
A series of nine housings were built for a depth of 2000M, to be attached to Elephant Seals. These are designed to carry a MicroTrack II recorder, timer board, and custom Lithium battery packs. The photo shows the first prototype, ready for pressure testing to 3000 psi.

Photo Credit: Ken Sexton.

Deep Audio Housing for Elephant Seals (2009)
Click to enlarge
 
This photo shows the inside construction of this unit. The door is 1.5-inch aluminum, with a double o-ring bore seal to the smoothed mouth of the cylinder. The battery packs mount on the threaded brass rods.

Photo Credit: Ken Sexton.

This photo shows the inside construction of this unit
Click to enlarge
 
This photo shows two of the nine units made in this run. Five of these were deployed on Elephant Seals to record ambient sounds while they were at sea, in four 24-hour blocks a week apart. The LARa units were recovered when the seals returned to shore after a 70-day foraging trip. This work was done under a permit form the Marine Mammal Commission.

Photo Credit: Ken Sexton.

This photo shows two of the nine units made in this run
Click to enlarge

Deep Laser Housing for Hercules (2009)
This customer needed to use a very powerful green laser as a light source for motion studies. The laser beam passes through a cylindrical lens to produce a sheet of light, seen at the upper left of this photo. The rectangular devices on the sides are positioning arms, shown in a compact position for shipping. At the near end is a switch to activate the laser. The white Delrin mounts allow final adjustment of the beam perpendicularity to a camera in a commercially made housing.

Photo Credit: Ken Sexton.

Deep Laser Housing for Hercules (2009)
Click to enlarge

BotCam DVR Housing (2008)
This housing was developed to enclose a hard drive and several electronics boards to serve as a Digital Video Recorder for an instrument that measures lengths of bottom fish in the wild. This housing is attached to a large frame that holds two video cameras set up as an exaggerated stereo pair with all elements of its geometry carefully measured. When a bait container is opened, the fish are attracted to the instrument, are recorded by both cameras. Upon playback, the nose and tail of a fish is digitized in the corresponding left and right frames, allowing the researchers to calculate the length of the fish.

Photo Credit: Ken Sexton.

BotCam DVR Housing (2008)
Click to enlarge
 
This photo shows the inside details of the housing. The electronics boards are mounted to a tray, with a hard drive on a removable mount on the far side. At the bottom is a custom battery pack of 20 C size NiMh cells. On the outside of the door are underwater connectors for the inputs of the two cameras.

Photo Credit: Ken Sexton.

This photo shows the inside details of the housing
Click to enlarge

Micro Rudar Audio Recorder Housing (2008)
This housing, made of 3-inch PVC pipe, coupler, and cap, is an inexpensive way to carry a MicroTrack II audio recorder and hydrophone to a depth of 800 ft. The hydrophone is mounted to the door, and mounts with a double o-ring bore seal into the door. The recorder is attached to the door tray, and a battery pack is underneath the tray.

Photo Credit: Ken Sexton.

Micro Rudar Audio Recorder Housing (2008)
Click to enlarge
 
The same housing shown with the door inserted. Note the stainless steel guard that protects the hydrophone from physical harm.

Photo Credit: Ken Sexton.

The same housing shown with the door inserted
Click to enlarge

Dissolved Oxygen Meter Housing (2008)
This housing is an adaptation of the Shallow EAR design, modified for greater depth, 300M. It holds a DO probe (the black device under the stainless guard), a signal-processing board and other electronics, and writes its data to a CF card. It is designed for repeated deployment for several days at a time. The unit is switched on at deployment time by removal of the red magnet, which closes a reed switch. This unit is used to study O2 content of waters off the Oregon coast, by attaching it to crab pots deployed by cooperating fishers in the area.

Photo Credit: Ken Sexton.

Dissolved Oxygen Meter Housing (2008)
Click to enlarge

Fifth Generation GPS Housing (2008)
Made for Long Beach Dive, this version was made by machining out a pair of clamshells from 2-inch thick Polycarbonate. There are no glued seams, and the housing is very durable. There is an o-ring seal between the two halves, which are held together by stainless latches. The customer installs his proprietary instruments inside the completed housing. The business card was placed inside to illustrate the clarity of the machining, necessary for the user to read the GPS screen and magnetic button labels inside the housing.

Photo Credit: Ken Sexton.

Fifth Generation GPS Housing (2008)
Click to enlarge

Direction Indicator Housing (2008)
A customer had a need for a housing for a 3-axis electronic tilt gauge to be mounted on an experimental tidal generation machine. This one was developed using a Schedule 40 5” pipe Tee and Cap, plus a base and double o-ring sealed door. There is an o-ring sealed adapter plate on the base for an underwater connector for power in and data output.

Photo Credit: Ken Sexton.

Direction Indicator Housing (2008)
Click to enlarge

pH and DO Meter Housing (2008)
This 160-ft housing was made for an Orion Star 3 meter with special underwater probes for pH, Dissolved Oxygen, and Temperature. On/Off control at left and ReadNow trigger for right thumb on handle. Size reference is quarter near probes. Customer was University of North Carolina at Wilmington, Drs. Alina Szmant and Robert Whitehead. They will be testing the chemical properties of shipwrecks underwater.

Photo Credit: Ken Sexton.

pH and DO Meter Housing (2008)
Click to enlarge

The third generation Deep EAR (2008)
The underwater audio recording devices now features a sheetmetal tray for the instruments inside, a stainless steel guard over the sensitive hydrophone, and a magnetic reed switch for the power circuit. The switch allows the unit to be set up and tested in a lab environment, then deactivated by placing the red magnet read the switch for transportation the deployment site. When ready, the researcher simply unscrews the magnet in the red plug, activation the unit.

Photo Credit: Ken Sexton.

The third generation Deep EAR (2008)
Click to enlarge

Orion 4 Star Housing (2008)
This housing was for an Orion 4 Star pH/DO meter. It has connectors for probes for Dissolved Oxygen, pH, and Temperature. The housing has controls for On/Off and Take Reading Now, and is designed for operation to 300 ft.

Photo Credit: Ken Sexton.

Orion 4 Star Housing (2008)
Click to enlarge

Housing for PulseStar Metal Detector (2008)
This 160-ft housing was made for a treasure hunter looking at shipwrecks in the Great Lakes and along the Eastern Seaboard of the US. It uses a 4 foot square loop (not shown), and can be handled by a single diver. It uses underwater headphones supplied by the customer.

Photo Credit: Ken Sexton.

Housing for PulseStar Metal Detector (2008)
Click to enlarge


See More Examples of Underwater Instrument Housings
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