Tuffboy

TuffBoy

NOTE for admin : I have been working on this project form then 70+ hrs i have made so much progress and learned so many things you asked me add the things like bom and how will the make this those things are now added also your review stats that "Some of your journals although they have what you've done, kind of doesn't justify why you got the hours and has a brief explanation" I understand that you need proper journals and all i have tried to make the journals bigger and they describe what i did but thee main problem i myself does not remember what i did like 2 or 3 weeks ago that's why i can't full full fill your journal criteria also you guys states that the hours does not justify tbh i am very very new in this tech field i learned kicad from ground zero that's why it takes time to make the pcb to find the parts for the pcb design i am not a pro at the end so if you check any lapse with the devlog you can see that was working only not afk but my speed has now increased also some of the journals were i shifted to linux the lapse are not there becuase i thought that lookout only works in windows so pls keep that in mind. I really hope that this time my project gets selected.

A handheld multi-tool inspired by the Flipper Zero, but built around the ESP32-C5 Devkit C with Dual Band (2.4GHz + 5Ghz), and a big idea: an expansion port that lets you bolt on a whole second microcontroller (Black Pill, or basically any 3.3V dev board).

This is the part that makes TuffBoy ~200× more flexible than a Flipper — instead of being stuck with only 2.4 GHz WiFi we have a breakthrough with the support of 5GHz, opening the door to WiFi security testing, along with support for plugging in whatever co-processor the task needs.

TuffBoy so far:

Circuit diagram:

3d model of the device

3d render, of back

pcb layout

the 4-pin expansion connector

Schematic

what is this

So the Flipper is cool but it's not that good in base form and expensive, and things like M5 Stacks can't really do proper wifi work (absence of 5GHz). TuffBoy is my take on what that device should be:

• ESP32-C5 as the main brain — wifi 5GHz/2.4GHz + BLE, USB-C
• nRF24L01+ for 2.4GHz radio stuff
• CC1101 for sub-GHz (300–928 MHz)

• TFT — a 2.8" inch which is fully touch, no button, which makes it look like a small phone.

It's being made with the help of Hack Club.

How to make one:

To make one just see the circuit diagram images and copy it then add the script which is in the firmware folder in the esp32 c5 that's all as simple as you see. How will i make it i preffer to make this on a zero pcb first that will hlep me fix any problems with the pcb. Also if you want to know the wiring here its is:

Wiring

Main Controller

The TuffBoy is built around an ESP32-C5 DevKit-C. The TFT, CC1101, and nRF24L01+ modules communicate with the ESP32-C5 using SPI, while the 4-pin JST-SH connector provides a UART expansion interface.

Pin Assignment

Note: GPIO numbers are the proposed firmware/pinout assignment for TuffBoy. Verify them against the exact ESP32-C5 DevKit-C board and your final PCB before manufacturing.

2.8" SPI TFT + Touch

The TFT uses the ESP32-C5's SPI bus.

Touch Controller

For a typical XPT2046-style SPI touch controller:

The TFT and touch controller share the SPI clock, MOSI and MISO lines. Separate chip-select lines allow the ESP32-C5 to communicate with each device independently.

CC1101

The CC1101 uses the same SPI bus as the TFT and touch controller.

The CC1101 SPI bus is shared with the other SPI peripherals. Its dedicated CS pin is used to select the CC1101.

Important: The CC1101 module must be operated at the appropriate supply voltage for the specific module. Do not assume a 5V logic interface is safe.

nRF24L01+

The nRF24L01+ also shares the main SPI bus.

The nRF24L01+ uses the shared SPI bus while CSN and CE remain dedicated to the module.

Power note: The nRF24L01+ can be sensitive to supply noise. Place a decoupling capacitor close to the module's VCC and GND pins.

4-Pin JST-SH Expansion Connector

The 4-pin JST-SH connector provides power and a UART interface for an external 3.3V-compatible microcontroller or expansion board.

Connector Layout

JST-SH 4-Pin

┌───────────────┐
│ 1 │ 2 │ 3 │ 4 │
└───────────────┘
  │   │   │   │
  │   │   │   └── RX
  │   │   └────── TX
  │   └────────── 3.3V
  └────────────── GND

the uart extension (the big idea)

Every flipper-clone has the same problem: you get one MCU and that's it. The TuffBoy has an expansion port for a second microcontroller:

• plug in a STM32 Black Pill (or any dev board that runs on 3.3V logic)
• the ESP32-C5 stays the brain (UI, wifi, displays) and the STM32 becomes a co-processor for whatever you want — real-time tasks, extra peripherals, other radio stacks, whatever you can think of
• the connection is a simple 4-pin jst connector: TX, RX, 3.3V and GND (J1 on the board) — no special hardware, just serial
• since it's just TX/RX + power, basically any 3.3V board fits — black pill, another xiao, whatever you have lying around

With this we can add basically anything we like, without redesigning the main board every time. New feature = new daughter board / new firmware, not a new device.

wifi hack firmware (The core idea)

The main focus of the software is my "wifi hack" firmware — the whole reason I started this. Wifi security testing is weirdly hard to do on existing pocket tools; the Flipper can't do it properly at all and M5 stacks are clunky for it as both lack a 5GHz radio. The goal is a firmware that makes wifi security testing easy, straight from the device UI:

• scan / monitor mode
• deauth + handshake capture workflows
• works on 2.4GHz AND 5GHz wifi — the esp32-c5 has 5GHz wifi built in, and basically no pocket tool does 5GHz. flipper can't, m5 can't. this is the rare one.

obviously: use it only on networks you own or have permission to test. this is a learning tool, not a crime stick.

catching up to the flipper (then passing it)

The flipper has a bunch of stuff mine doesn't (yet). here's the honest status on each:

So the plan: everything the flipper does gets added over a few board revs + firmware, and the flipper literally can't do wifi (or take a second mcu) — that's where tuffboy stays ahead.

software status

The project currently has two firmware paths. You can either use the included TuffBoy starter/custom firmware or clone Bruce and continue from that firmware project.

Use the TuffBoy firmware

The native starter firmware is located at firmware/TuffBoy/TuffBoy.ino. It is written for the ESP32-C5 Arduino framework and currently provides:

• boot diagnostics and chip information
• configurable LED status indicator
• expansion UART test messages
• I2C bus scanning
• Wi-Fi station mode and nearby-network scanning
• a serial command interface (help, status, wifi, i2c, led, and more)

The LED, I2C, and expansion UART pins are defined as constants at the top of the sketch because the final pin mapping may change between board revisions. The sketch uses the ESP32 Arduino framework APIs and the built-in Wire and WiFi libraries.

The project also contains custom firmware developed specifically for TuffBoy, which will be used as the project continues beyond the initial hardware testing stage.

Clone Bruce firmware

The firmware/Bruce Firmware Cloner.py script downloads the Bruce firmware into a Bruce/ directory. It requires Python 3.7 or newer. Git is used by default, or the --zip option can download an archive without Git.

# Clone Bruce into the current directory
python3 "firmware/Bruce Firmware Cloner.py"

# Shallow clone into a chosen directory
python3 "firmware/Bruce Firmware Cloner.py" -d ~/projects --depth 1

# Download Bruce as a ZIP archive instead of using Git
python3 "firmware/Bruce Firmware Cloner.py" -d ~/projects --zip

Useful options are --branch for a specific branch and --deps to install the Python build dependencies used by Bruce. After cloning, follow Bruce's own board and build instructions in its repository.

CAD and enclosure

The PCB uses 3D CAD models of the individual components mainly for visualisation of the PCB and complete assembly.

The individual component CAD models used in the PCB 3D model were downloaded from GrabCAD. These models are used to represent the physical components and their approximate placement in the complete assembly.

The TuffBoy cover/enclosure was made according to the requirements of the project and the completed PCB. The cover was made externally according to the required dimensions, component placement and mechanical requirements, and the STEP file was provided for use with the project.

current progress

• part selection + custom symbols/footprints (esp32_c5 lib: XIAO SMD footprint, cc1101, oled)
• schematic — all blocks placed (mcu, 2 radios, 2 displays, 4 buttons, battery + headers)
• board outline + placement
• first hand-routed nets (radio area, battery area)
• finish routing + ground pour
• decoupling caps
• DRC clean + renders
• stm32 expansion connector on the board (J1 = TX, RX, 3V3, GND)
• PCB design completed
• custom TuffBoy firmware started
• enclosure / cover STEP file

files

tuffboy/          the kicad 10 project (sch + pcb)
tuffboy.pretty/   third-party libs (xiaosymbols, ssd1306 footprints etc)
CAD/              step models (esp32-c5, nrf24l01, cc1101, oleds, 603040 battery)
images/           pcb renders + board pics
firmware/         TuffBoy custom firmware and Bruce cloning script
BOM.csv           bill of materials
Front Housing.step
Rear Housing.step
assembly(full)-reduced.stl
tuffboy(without case)-reduced.stl

Open tuffboy/tuffboy.kicad_pro in kicad 10 and you're good.

BOM

Bill of Materials

Estimated Project Cost

Total: ₹5,782 INR
Approximately: $60.27 USD

Prices are approximate and may change depending on availability, shipping, taxes, and seller pricing. Buy links are in BOM.csv

credits

• completely made by ishant dahiya
• inspired by the Flipper Zero (obviously)
• Hack Club for the support
• individual component CAD models sourced from GrabCAD for PCB visualisation
• TuffBoy cover/enclosure made according to the project requirements and provided as a STEP file

Images

Image	Description
	3D model of the device
	USB-C connector detail
	PCB layout
	Schematic
	Top view of the device
	SD card slot
	Back cover
	3D render of back
	Top cover
	4-pin JST expansion connector
	Back view of the device

hardware: PCB completed · software: custom firmware in development · last updated Sep 2026