List of materials:
- A hardback book
- Glues - Elmer's glue, superglue, kid's push-up stick glue. You don't need all 3 but I found it easier to use different types in different places.
- Glue brush
- Wax paper
- Rubberband or masking tape
- Rare earth magnet and a 1/4" bolt washer (optional)
- Straightedge, pencil, ruler
- Exacto knife
- Bandsaw or scrollsaw
- 3/16 bandsaw blade
- A nail or staple gun
- Flocking kit including mini-flocker, adhesive & flocking felt
Step 1: Grab a Book & Add a Magnet
To fasten the book shut you can bury a magnet and metal washer prior to doing any gluing. On the corner of the cover, peel back the liner and mark the location for the washer. Make sure this will not interfere with your cut line as your magnet will be in the same spot within the books pages. The center of the washer is roughly 1/2" from both edges. Use an exacto knife to cut into the cardboard cover and glue the washer in place and then the liner.
For the rare earth magnet, start cutting your holes on approximately the 8th page. A 1/8x1/2" magnet is enough. Since the pages are smaller than the cover, the center of the magnet is 3/8" from both edges. In my case, the book was so close to the size of the iPad that the magnet is quite close to the edge. As long as the magnet is not in the way of the saw blade the magnet can be placed anywhere. With the magnet in place, glue the corners of 3-4 pages over the top of the magnet to secure. The sides of the book will be glued in the next step.
Step 2: Planning the Inside and Gluing the Outside
To protect the outside cover and to keep from gluing the entire book into a block, wrap wax paper around the front and back covers. You can secure the wax paper with either a rubberband or tape (or apparently both in my case).
With the covers protected, mix up a bit of Elmer's white glue and water at roughly 2/3 glue & 1/3 water. You are trying to get runny glue and the mix isn't critical. Simply brush the glue mix on the outside of your book's pages with a brush. I soak it pretty well by going over it a couple times. When you are finished, close the book and stack some weight on top of it to prevent wrinkly pages. Let the book dry for a couple hours or ideally overnight.
Step 3: Nail the Book Together
In retrospect, I would combine the right shoulder with the button access circle in the upper right corner. It would have been simpler to glue a single piece and look more finished. Check out pics of another book at the end of this instructable to see what I mean.
To keep the pages together once you have cut them out, nail or staple them together with a power gun. I use 6-8 crown staples which penetrate about 3/4 of the book's thickness. Nail the front and the back to make a solid block.
Step 4: Bandsaw Time!
Step 5: Glue the Book Body
Step 6: Make the Inside Shoulders
When it is dried you can return to your saw and cut the shoulders you marked previously. Next you'll need to remove pages from the top of the shoulders until they are the ideal height for your iPad. Go slow and if you take off too many pages just glue them back on. When you are happy with the fit of your iPad glue the inside edges of your shoulders with runny glue.
When your previous gluing has dried it's time to glue the shoulders inside your book box and also glue the interior walls together. Apply Elmer's or wood glue to the bottom and outside surfaces of your shoulders and put them in place. In my case, I also glued the circular pieces in the round cutout. With runny glue, coat the inside walls of the box and let it dry.
Step 7: Finishing the Interior
Next it's time to flock the inside. Flocking is very easy and has many applications. Essentially the idea is to paint on the adhesive and then flood the interior with felt flocking. There are many different colors of flocking to choose from including red, green, blue, black, etc. The tall yellow can is called a "mini-flocker" and has holes in one end. Fill the lower half with flocking and then as you push the halves together - flocking shoots out the holes on the end. It makes it very easy to apply an even coat to all surfaces. Have everything ready to go when you start applying adhesive as it sets up in 10-15 minutes. Let the flocking cure for 12-24 hours before you remove any excess.
In the pictures you can see that I applied purple painters tape to the surface in hopes of keeping the top page clean. It didn't work. The blue adhesive seeped under it anyway. In the next step you'll see how to fix this problem.
Step 8: Cover Your Trail
This step covers your entry cut line and glue messes. I used my trusty kid's glue stick for this step. Glue the page in place and let it dry before cutting the center out with an Exacto knife. And your done!
Step 9: Find a Quiet Spot and Surf!
Make one, you'll love it!