Introduction: PANZERHANDY - the Armoured Cell Phone

Picture of PANZERHANDY - the Armoured Cell Phone

How many times I broke a mobile phone by just letting it fall on the ground or - everybody gets angry, sometimes - while throwing it to the wall or someone's head...

Too many, many too many. Even my strongest Samsung shockproof didn't resist, finally.

Mobiles are fragile, too fragile, and need our protection.

So I decided to develop an armour - a panzer!

An armour will
1) protect the inside
2) make you think twice before throwing it
3) be more effective when the phone goes ballistic

Low-cost, shockproof. And, don 't forget, cool!

Needs:
- some scrap or, in my case, a few metal sabots used in woodconstruction stuff
- an old mixer
- all the metal working gear you can grab

Step 1: Preparing the Sides

Picture of Preparing the Sides

Sabots are cool stuff: cheap, and already plied. Only some cutting, welding & grinding to make the pieces you want.

Step 2: Welding the Box

Picture of Welding the Box

Cutting, welding, grinding, again.

Step 3: Adjusting Height

Picture of Adjusting Height

To properly cut the sides of the box I prepared a box outside the box with the thickness I wanted.
Some grinding and the job was done.

Step 4: Welding the Bolts

Picture of Welding the Bolts

How fixing the bottom to the box? Love-less bolts, of course, welded in the box.

Step 5: Preparing the Bottom

Picture of Preparing the Bottom

Cutting, drilling, countersinking, sanding, fixing.

Step 6: Preparing the Hinge

Picture of Preparing the Hinge

Or how two two male-female hinges become one male-female-male hinge.

Step 7: Fixing the Cover

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Welding the two males to the cover, and the female to the box.

Step 8: Going Arty

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No armour without appropriate helmet. Since I liked the combination of steel & copper of the popular 'templar helmet' I decided to do something in that way, my way (and to avoid religious symbols but that's another discussion).

Step 9: Transforming the Mixer

Picture of Transforming the Mixer

Mixers, taps & so on are made of copper.

I'll show you two ways to obtain a large copper piece on the cheap:
- cutting & flattening a copper tube
- dismantling a mixer

I those the second because I wanted it to be relatively thick.

Step 10: Copypasting

Picture of Copypasting

Transfer the image to the copper piece & start cutting & sanding.

Step 11: The Big Drilling

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Copy the image on the box.
Drill the holes for speaker, plug & image in the box.
Use a dremel countersink to enlarge (although I wasn't satisfied at all of this tool).
Use a classic file to enlarge better.
A bit sanding finish the job.

Step 12: Add 'the Nose'

Picture of Add 'the Nose'

I'm a big fan of sef-drilling screws.
Some pre-drilling in the nose and there you go.
Cut the excess & put a few points of welding on the back to assure that the screws will never go away.

Step 13: Drilling the Pad

Picture of Drilling the Pad

Copy the configuration of your mobile on a transparent foil, glue it VERSO in the box, point, drill & file.
Now you'll sure that behind each hole there will be a button.

Step 14: Making the Keypad

Picture of Making the Keypad

Put a screw in every hole.
Fix them with a bolt.
Cut & grind.
Remove the bolts: you'll become tiny screws that will perfectly have the rigt size.

Put some grease on the back of the pad to prevent the glue will stick to it.
Put the screws in place.
Take a piece of transparent foil with some glue.
Put in on the back & let it dry.
Now you'll have a real steel keypad.

Note that I polished the whole before fixing the keypad.

Step 15: Assembling

Picture of Assembling

Put some foam tape inside the box to maintain the phone in place & screw the cover.

Step 16: Call Me Maybe!

Picture of Call Me Maybe!

Finally, does the steel keypad work?

It works!!!

Hope you liked this one, and thanxxxxxxxxxx for whatching!

Comments

chaosfts (author)2015-08-02

This is the coolest phone I've ever seen! Thank you bricobart!

laffinm (author)2014-05-02

You should engrave the metal around the buttons so you know what numbers they are

vincent7520 (author)2013-12-10

Niiice when boarding a plane ! … 

Advar (author)2013-10-10

Star Trek Steampunk!, :O
Sweeeeeet!

q3qyuu (author)2013-05-09

Can this be applied to a qwerty phone?:D

IR0NxLEGEND (author)2013-04-15

Is there any way to easily waterproof it?

bricabracwizard (author)2013-04-01

This is such a great 'ible! It looks so medieval that I want to get a horse and armour to match and trot down the Main Street calling up anyone I can think of.......will it withstand a sword blow?

It will, great knight - maybe I should call this i'ble 'sword-proof'!
My french friends have an expression for making a phone call 'giving a phone hit', they say. Now I understand why everyone is afraid when I promise I'll give them a 'phone hit' ;-)

Yeah....on iPhone there is an app that is called bump, when you knock phones together you can transfer files or photos...with this you could demolish the other phone.....but you would only use this for good not evil? :-)

Of course great knight, unless it's a Japanese whaler who's calling me! Bump it!!!

jumper17 (author)2013-04-02

I'm honestly surprised that nobody's even mentioned the 'Nokia' brand yet.

FriendOfHumanity (author)2013-03-26

Wow; very nice job.
I particularly like the keyboard.


is the signal affected at all by the case ?

Thanx! The signal seems to be the same as before in 90% of the calls, honestly. Sometimes there's some loss, even when just before it was at full power.

pokemech (author)2013-03-24

Now for the true test, give it to Chuck Norris...

bricobart (author)pokemech2013-03-26

I'll give it to my yak ;-)

Mr. Swiss Gartner (author)2013-03-23

Looks cute!

Thanx mate!

About This Instructable

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Bio: I made a beer mug with only a knife & a hatchet. I think that says a lot about me.
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