Amplifier Dock is a passive amplifier and docking solution for iPhone and iPod touch that utilizes the shape and material of an ordinary ceramic bowl. Designed for disassembly, the ceramic bowl may be reused, steel hardware may be recycled, and hardwood/ wool felt may be left to biodegrade. This is my first project as a 2013 Artist in Residence at Instructables.com.
Step 1: Materials and Tools
• Ceramic cereal bowl about 6.25" diameter and 2.5" height
• 2 10-32 thread 1" length flat head phillips machine screws
• 2 10-32 thread wood tee nuts
• A small piece of 1/8" thick wool felt, at least 2.5" sq
• A block of hardwood you can cut down to 16" x 2.3" x 3/8"
• A $.10 dime (totally serious)
• Wood planer
• Table saw
• Chop saw
• Belt or disc sander
• Drill press
• Drill bits
• Forstner bit,
• Countersink bit
• Calipers or tape measure
• Block sander
• Medium and fine grit sand paper
• Wood glue
• Craft glue
• Mallet or dead blow hammer
• X-acto knife
• Metal ruler
• Masking tape
• Phillips head screw driver
Here's where I got my bowl and wool felt:
Step 2: Plane Hardwood Block to 3/8" Thickness
First order of business: plane to 3/8".
Step 3: Cut to 2.3" Width
Use a table saw to cut your 3/8" piece to a 2.3" width.
Step 4: Cut the Base, Spacer, and Cap
I have provided a technical drawing (.jpeg and .pdf) to serve as a reference for the coming measurements and cuts.
Step 5: Countersink Base for Tee Nuts
Step 6: Drill Out the Base
Step 7: Countersink the Cap
**Insert your wood sandwich into the vice (base side up) and use a small bit to drill a pilot hole all the way through from base to the cap first. This will save you from having to measure again onto the cap like I did.
Now flip your wood sandwich right side up, get your countersink bit, and carefully drill out countersink holes in the cap for the flat head screws.
Step 8: Drill Through All
Step 9: Insert Tee Nuts
Step 11: Round the Corners
It's coming together now! Go ahead and stack the cap on top, insert the machine screws, and see how it looks!
It just so happens that the rounded corners on an iPhone/iPod are almost exactly the same size as a US dime. Grab ten cents and trace around the four corners of the cap and rear 2 corners of the base. Use a belt or disc sander to carefully sand down your corner. Remove the cap to hit its rear corners.