This Instructable will guild you through the process of making a kick ass battery cover for your lost or broken small device battery cover. This works with almost everything I own except for some TV remotes. In this Instructable I'm going to show you how I made two different styles of battery covers. I use two different examples not because I feel like you can't adapt this to any device but because I have a mixed array of pictures from two different devices! I hadn't even realized that this was the best Instructable ever until I was about mid way through the first cover.
The Instructable hopefully will become a launch point for many more on the use of old "Credit Cards". I use the term "Credit Card" as a generic term for any small piece of plastic that various company's hand out, some for free and some for your soul. You can get a stock pile of these by going to any store that offers a club card or membership cards. For this Instructable I will be using a gift card from Game Stop and a Wells Fargo ATM.
Is there a better use of a Credit Card out there? YOU TELL ME!!!
Step 1: Materials Needed
2--- "Credit Cards" or like card. Any plastic card will work for this Instructable! I would recommend at minimum two of these before starting as I over cut the first one I made.
Note: From here on out I will be referring to the card as a "credit card" for simplicity.
(you can get these for nothing at places like the grocery store or any other place that furnishes "club cards").
1---- Pair of scissors.
1---- Device that heats things up i.e.. Lighter, matches, the stove, heat adjustable soldering iron...... Gas Stoves are best because they serves two purposes, heat and a platform for bending, I will be using a combination of the lighter and the gas stove.
1---Medium C-clamp-- Depending on the technique used you may or may not need this. Read ON!
1---Sharpee Pen or felt tip pen
1---Crap in "eye removal tool", referred to as "ERT" from here on out. Or you can use a nail, a paper clip or any other small cylindrical metal object.
1---Something straight edged for aligning your marks. I used another credit card for this as the size was appropriate and it had a nice square edge.
*Optional or Additional
1---Can of Plasti-Dip ( even if you don't plan on using this stuff for this Instructable I would suggest picking up a can as soon as possible, it has thousands of uses ).
1---Set of alligator clips with wire tying them together
1---Clock with pendulum arm or as I call it, "My Centrifuge".
1/2---Set of Common Sense (perhaps the hardest thing to come by for this Instructable). Perhaps this should be the first on the list or on any list.
Please See All Squbbles (square bubbles) for additional instructions and information
As a warning to all, this Instructable involves the use of heat and sharp objects so please take care and focus on what your doing while doing.
Step 2: Measure Twice
Please see pictures and hover over picture Squbbles (Square Bubbles)!!!
Step 3: Cutting
Step 4: Now We Bend, Mold, Stab and Shape the Rockband Controller Cover
TURN THE STOVE OFF BEFORE THE INTRODUCTION OF PLASTIC TO THE AREA, PLASTIC IS FLAMMABLE AND THE SMOKE IS TOXIC.
***For the Rockband Controller we only need a slight bend on the two tabs to get the Credit Card to sit flush with the back of the controller. Then we take the ERT, heat it up and poke a hole in the area where the screw hole is, I just kind of guesstimated (can you believe that "guesstimated" didn't trigger spell check) where the hole goes, it seemed to work out well for me. If your comfort level isn't high enough you can set the cover back in the controller and mark out where it should go.
I suggest doing this in a ventilated area as there is a risk of creating toxic smoke as the heat level required to melt plastic is higher in this step. I didn't get any smoke through this project but I don't want you to get yourself a case of the cancer. As an alternative you can use a Dremel tool or drill for this but then there is carcinogenic dust. Lesser of the two evils?
Step 5: Rockband Controller Finished
Step 6: Now We Bend, Mold and Shape the Mouse Cover
For the second bend it goes pretty much the same as the first except this time we need to make sure that the depth of the bend matches the depth of the slot on the mouse. For this I just set the tabs in the slots and did another guesstimated measurement of the depth that it set in.
Step 7: Mouse Battey Cover Finished or Maybe Not
Step 8: Introducing Plasti-Dip
This is not going to be a step by step on the application of Plasti-Dip as the can explains the process well.
First we are going to get out our alligator clip and attach it to the very edge of our Credit Card Cover.
Next we open up our Plasti-Dip and slowly dip our cover in. Make sure that you have coated the whole thing and then slowly pull it back out.
Now simply attach the other end of you alligator clip helper to something that can support it so it can dry. Notice that I have placed a piece of paper under the dipped cover to catch any thing that may drip off of the cover. This stuff sets up on the outside fairly quick but there is the chance that you could get some running.
You will notice that when your cover starts to dry it will form a "skin" of dried plastic. Now is the time for you to press on the "skin" to smooth out the coating as there will be a couple of high spots on the surface.
To cure this unevenness there is another way that I have found, its gonna seem silly but it works. My centrifuge. After the initial skin has formed, take your alligator clip end and attach it to something that is going to create some additional gravity. As you can see from the pic it doesn't take much as I've used a cheap clock. You can use a ceiling fan set on a low setting.
Step 9: Finished Product
Destroy those credit cards today and thank me tomorrow!
If you like this tutorial or find this to be useful please post feedback as it took me about six months to write this Instructable!