In this instructable, you will learn how to change the opening in the bottom of an acrylic iPhone case to accept a charging accessory that is otherwise too wide for it.
This photo shows the case itself (the pink thing in the back is a stick-on LCD flashlight) and the charger. The charger is clearly too wide to fit through the bottom, making it impossible to charge the iPhone in the case.
Step 1: Tools, and safety first
For this instructable, you only need a Dremel or rotary tool (I used my jeweler's rotary tool) and a compatible sanding accessory. I tried a few different accessories, but for the whole instructable, I only ended up using the one pictured below. It fit in the opening and did the sanding I needed.
Be sure to wear safety glasses and a mask any time you are sanding if you value your ability to see and breathe. Seriously. Plastic dust is pretty toxic.
Oh, and I had my iPhone playing music in the background while doing this - awesome!
Step 2: Sand to fit
Slowly sand the opening to fit the accessory. I prefer a variable-speed rotary tool because it gives you more control. The foot pedal is ideal. Test the fit often. It took me about 15 minutes to get the right fit, and I had to test it with the charger attached a few times to get it perfect.
Step 3: Finishing up
The sides you have sanded will be a bit rough. If you have a polishing accessory and want to polish it, go for it. None of my accessories worked for that. Probably a fine sanding piece would work well, but I didn't bother because the rough insides are totally unnoticeable when the iPhone is in the case. Be sure to get off any plastic bits/sharp edges with the sander.
Clean off all the plastic dust - a microfiber cloth works well for this. And make sure it continues to charge - my charger would gradually get pushed out until I made the fit just right.
Enjoy your in-case charging! No more having to take the case apart to charge on the go!