This is how I make an ipod Line Out Dock (LOD)
This is not a definitive guide by any means. This will not work on all ipods. Some newer models than mine (3rd generation nano) need pins 15+16 left in and bridged with solder. And some need resistors soldered in. There are some realy good forums for this on Headfi.com if you need to do some research.
Now, LOD? This takes an audio signal out, bypassing the internal amplifier. And in this case, to an external headphone amplifier.
This one differs from most in that the cables exit from the left hand side and the connector body is made from scratch.
Some of the photos I took are not great and others were deleted from my phone - softwear error!
Hope this is useful.
Ipod glue together connector - from Quables
Mundorf gold 0.5mm / 24awg solid core wire - Online
24 awg OCC Solid core copper - Quables
Neutrik 3.5mm stereo Jack plug - online auction
Bootlace - both thick and thin.
PTFE Tape - plumers merchants
8mm OD brass tube - model shop
2x Brass pet address barrels - pet shop
Heat Shrink tube
2 part epoxy resin glue
Needle nosed pliers
Pin Vice plus drill bits
Stanley / craft knife
Wet and dry paper
Step 1: Pulling pins
For this LOD you only need pins 2, 3 and 4 on the ipod connector. This means that the other 27 need to be pulled out.
Pins are laid out as follows from left to right if looking at the connector from the front - the side that faces towards you as you look face on at the iPod:
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Pulling them ouy is easily done with a pair of needle nosed pliers. Take your time and make sure you get the right ones! These can be re inserted if needs be but it's far easier to leave them in.
Once these are out use a 'Dremel' with a cut off wheel to carefully cut away a portion of the connector closest to the pins. Then use side cutters to cut the pins down.