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Step 2HOW TO INTEGRATE AN IPOD DOCKING CRADLE
As mentioned in the background, one of the goals was to integrate an iPod docking cradle. Why not just buy one and mod it to fit? I use a case on my iPod and most off-the-shelf docking cradles require you to remove the case prior to docking it. Who wants to do that? I decided to build one from scratch that would fit into the boombox.
Parts required:
1/16" Acrylic sheet - Tap Plastic 2'x2' $7.00
Acrylic cement - Tap Plastic $3.40
1 iPod 30 pin Connector - Sparkfun http://www.sparkfun.com/commerce/categories.php - DEV-00704 $4.95
1 1/8" stereo jack - Radio Shack - 274-249 $2.99 Optional
Here's another hint. Buy the Sparkfun docking connector! In fact, don't buy the model I bought, they have a new one called the PodBreakout, DEV-08295, $14.95 which makes soldering these little buggers much easier. I mentioned "do-overs." I don't remember how many mistakes I made with this connector (DEV-00704). Several times I accidentally broke off the internal pins after installation. I ended up having to pull out pins from pins I knew I wasn't going to use to replace the ones I broke. By the way, if you do get model DEV-00704, I found it much easier to pull the pin out of the connector body, solder and heat shrink the wire and then replace it back into the body. There's less of a chance of soldering two adjacent pins together.
Don't think you can cut corners by using an iPod connector from one of those off brand iPod chargers. I bought two of these and found they only contain the pins for charging your iPod. They do not have the pins for the Left and Right Audio Line Out (pins 2, 3, 4). iPod Docking Connector Pinout Save yourself some heartache, just buy the Sparkfun docking connector...
At this point, pull out the cassette tape mechanism. Mine had four screws and two connectors. Now you have lots of space for a docking cradle.
The fabrication of the iPod docking cradle is straight forward. Basically, you are building a "box" out of 1/16" acrylic sheet. Find a location for the cradle. I have an iPod Nano 2G so even with its case, it was slim enough to fit where the mechanical cassette tape buttons used to be.
After you've chosen a suitable location, mock up the box in cardboard then transfer it to the acrylic sheet. Cut it out and glue it together using the acrylic glue. Cut a hole in the bottom so the docking connector will fit snugly in the hole. Glue this in place only after you're 100% sure all connections are working correctly, see below steps.
I had to grind down some plastic bits inside the boombox enclosure which wasn't easy because it was hard to get a big file into a tiny space. In the end, I used a cardboard nail file that was broken in half. A Dremel would have helped but I don't have one.
I also had enough room to install and On/Off switch (red button) and a stereo Line In jack (see STEP 4, below). Before gluing to the boombox you can spray paint it like I did.
Parts required:
1/16" Acrylic sheet - Tap Plastic 2'x2' $7.00
Acrylic cement - Tap Plastic $3.40
1 iPod 30 pin Connector - Sparkfun http://www.sparkfun.com/commerce/categories.php - DEV-00704 $4.95
1 1/8" stereo jack - Radio Shack - 274-249 $2.99 Optional
Here's another hint. Buy the Sparkfun docking connector! In fact, don't buy the model I bought, they have a new one called the PodBreakout, DEV-08295, $14.95 which makes soldering these little buggers much easier. I mentioned "do-overs." I don't remember how many mistakes I made with this connector (DEV-00704). Several times I accidentally broke off the internal pins after installation. I ended up having to pull out pins from pins I knew I wasn't going to use to replace the ones I broke. By the way, if you do get model DEV-00704, I found it much easier to pull the pin out of the connector body, solder and heat shrink the wire and then replace it back into the body. There's less of a chance of soldering two adjacent pins together.
Don't think you can cut corners by using an iPod connector from one of those off brand iPod chargers. I bought two of these and found they only contain the pins for charging your iPod. They do not have the pins for the Left and Right Audio Line Out (pins 2, 3, 4). iPod Docking Connector Pinout Save yourself some heartache, just buy the Sparkfun docking connector...
At this point, pull out the cassette tape mechanism. Mine had four screws and two connectors. Now you have lots of space for a docking cradle.
The fabrication of the iPod docking cradle is straight forward. Basically, you are building a "box" out of 1/16" acrylic sheet. Find a location for the cradle. I have an iPod Nano 2G so even with its case, it was slim enough to fit where the mechanical cassette tape buttons used to be.
After you've chosen a suitable location, mock up the box in cardboard then transfer it to the acrylic sheet. Cut it out and glue it together using the acrylic glue. Cut a hole in the bottom so the docking connector will fit snugly in the hole. Glue this in place only after you're 100% sure all connections are working correctly, see below steps.
I had to grind down some plastic bits inside the boombox enclosure which wasn't easy because it was hard to get a big file into a tiny space. In the end, I used a cardboard nail file that was broken in half. A Dremel would have helped but I don't have one.
I also had enough room to install and On/Off switch (red button) and a stereo Line In jack (see STEP 4, below). Before gluing to the boombox you can spray paint it like I did.
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