Quote:
Originally Posted by PocketGoods
Of course I am interested in your design ideas for PB360, ideas for holding syste and work-in-progress photos. I think I could help you to manufacture your cover as soon the prototype will be ready.
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I wanted to make a cover similar to this:
http://www.bookeen.com/shop/productd...?ProductID=443
I have purchased a piece of luxurious thick soft leather for the outside and a piece of much thiner soft leather for the inside lining.
I started by cutting two boards from a 1.5mm thick board of fiberglass laminate to the size of device. The board was used many, many years ago as an interface card for a PDP 11 clone. I have simply removed the printed circuit using and old chisel.
Manufacturers of similar covers, purses, leather articles use piece of cardboard as a reinforcement. I want my cover to actually protect my reader so I used something stronger. I would have prefered a carbon fiber laminate 1mm thick, but I could not get any. I was also contemplating using a 1mm thick piece of the best quality plywood and laminating a very thin layer of fiberglass cloth on both sizes. But the price of such plywood in my local model-building store was outrageous and I would have gained only a few grams of weight off the cover.
Please notice that there are two small pieces of steel inserted and glued to the board - this is the place where neodymium magnets will hold the cover closed. Next time I would use a little bit bigger pieces, because the magnets have to hold the covet through two layers of leather.
Along the border of boards I have drilled holes. Through this holes I will do an actual sewing with awl and two needles and two threads.
Then I have cut a thin strip of the laminate and glued a block of wood to it. Next I have carved the wood so it would fit the front curve of the device. I have made this piece of wood as thin as possible. I do not want to add bulk to the device.
I have made holes in the wood and glued in two neodymium magnets salvaged from an old harddisk. I had to grind the magnets to size. You have to grind magnets slowly on a wetstone grinder - with *lots* of water, so you do not heat the magnets. They would lose magnetisation (as I have discovered by trial and error ;-) )
Later the piece of wood will be glued to the bottom laminate board.
As a next step I will cover the reader in a clingfilm (a very thin polyethylene foil), put a little of silicone sealant on the wood and use reader as a form to make a nice thin silicone surface where the reader touches the wood.
Later I will post photos of how I plan to make the pouch from leather strips that will hold the reader in place. The pouch will cover practically entire reader except for the screen and center buttons.