Step 4: Final Assembly
First i needed to do final preps on the Electronics. So i shortened the wires to the Speakers and soldered them into place. I also shortened the wire for Audio input and soldered the Headphone jack on. The wires that go to the DC jack where stripped and tinned in preparation for soldering to the Jack. Next i soldered the Power wire from the Charging circuit to the speaker amp. The i stripped and tinned the Audio wires from the dock in preparation for them being soldered to the speaker amp. Now everything is ready to go in the case.
Now comes the hard part. The Right side Speaker went in first to prevent clearance issues when its time for the dock to go in. I flattened the Corners of the speaker so it can be held tight at an angle on the screws. I used a bit of hot glue to help lock the nuts into place and along the opposite side of the speaker to prevent vibrations. Next i put the dock through its mounting hole but left it unsecured. Then soldered the dock's audio cable to the speaker amp.
With that done it was time to get the electronics inside the case to the general area it needed to be in. I could then mount the Left Speaker, bending the corners and securing it with hot glue. Before i could mount the speaker amp i had to remove the LED indicator light and the small section of board it was attached to so the amp could fit into the face correctly. So i had to remove the Left speaker, pull the amp board out. make the cuts needed with my wire cutters and put it all back together again. Now i could mount the Speaker amp in place. The pots on the amp didn't have any washers or nuts so i had to pull one from a pot i had on hand. With the amp good and secure it was time to glue the charging circuit to the bottom of the case.
Now i could go about plugging in the USB cable to the dock. and securing it with hot glue. Then the dock gets mounted and glued into it slot. I had to use a couple of clips to hold the dock in place while i glues it. I noticed that my wire for the power plug came up a bit short so i had to solder on an extension to it. Next i attached the DC jack to the back side of the case and soldered the power wire in place. Before closing it up a hooked everything up and made sure it works. Its a good thing i did cause i wasn't getting any sound/ I i pulled the Left speaker and amp out. I noticed that when i removed the Headphone Jack from the board i left the L and R channels open. So i soldered in a couple of jumper wires and we where good to go. I also noticed the 7805 was getting pretty hot. So i found a heat sink and put a dab of thermal compound on it and bolted it to the 7805.
Now that everything checked out i attached the Audio input jack onto the back plate. I also covered the power and audio jacks with electrical tape in case anything made contact with the speakers.