You’d think just about all the permutations of adding a hub to the Raspberry Pi Zero were done. But you’d be wrong. [Daniel’s] approach is to put the Zero inside the existing case for the hub. The LogiLink hub used is in a nice metal case with mounting flanges on the side. It looks robust and not much like a typical consumer hub. This hack would serve well where the Zero and hub might take a few wacks.
It took some fiddling with the hub components but he made it work. The easy part was wiring the the power and USB test points on the Zero to the hub.
More challenging were the mechanical aspects to physically fit the Zero into the case. Four LEDs were removed since their only purpose was indicating if a cables were plugged into the hub. There are four electrolytic capacitors standing upright that occupied the space needed by the Pi. [Daniel] repositioned them to lie horizontally to provide room for the Zero.
With the Zero able to fit inside the case the next steps are to create mounting holes in the USB board and cut holes in the case to access the HDMI and USB ports and the SD card holder. Some finicky work with a Dremel provided the holes and the cutouts. Fortunately, the mounting holes on the Zero aligned with some open spaces on the USB board. If they don’t, some glue and standoffs might be sufficient.
The only aspect [Daniel] left for you to hack is access to the GPIO port. That would require another cutout to bring out a ribbon cable for controlling your world. After such a nicely detailed writeup with a plethora of pictures, he had to leave something for other hackers to do.