Introduction: Replacement Remote Control Battery Cover
After losing the remote control cover on a few remotes, I was tired of the sticky duck tape, rubber band/credit card solutions and decided to try to find a better alternative.
While 3D printing first came to mind, I hesitated because:
1. I don't actually have a 3D printer, and
2. I didn't want to spend hours measuring, 3D modelling, and go out to print at a maker space or public library.
Instead I found relatively easy, quick, and cheap (read FREE) solution by making a replacement remote control cover using aluminum siding samples you can pick up at the big box building supply stores.
Most remote control covers are small enough that the aluminum siding samples are more than enough to make a cover out of. They are also free (which is always nice) and you can even colour match to your remote!
It is easy to cut with metal shears and can be bent to most shapes.
I'll be showing how to make a remote control cover for the spring v-shaped latch type. I haven't tried making it for the tab type, but I think with some minor modification in the last few steps, it would work pretty well.
Step 1: Supplies and Tools Needed
-remote control that the cover is to be made for. For this instructable, I'm going to be making a battery cover for an original GameBoy that I found buried in my closet and happened to be missing the battery cover.
-aluminum siding sample (or aluminum flashing) with your choice of color. The aluminum must be at least 1" longer than the length of the remote cover.
-Safety Glasses: SAFETY FIRST....keep the metal shavings away from your eyes!
-needle nose pliers
Step 2: Make the Bottom Tabs
The bottom part of the cover has two tabs that fit into slots on the opening of the battery compartment.
First cut the aluminum so it fits the width of the opening. Using the permanent marker and metal shears, mark and cut so you have two little tabs about about 1/8" high.
With the needle nose pliers, bend the tabs downward just a few degrees,
Step 3: Mark Out the Top of the Battery Cover
Place the top edge of the aluminum against the top of the battery cover. Use the marker to mark where the opening is for the latch.
Now place the bottom tabs (from Step 2) into the slots, and mark the top edge of the battery cover and draw a line across.
Cut out the material from both sides leaving a long tab in the middle. This will be used to make the spring v-shaped latch.
You should now have the aluminum flashing nicely covering the battery compartment with approx 1" tab sticking out in the middle.
Step 4: Make the Spring Latch
To keep the battery cover in place, the latch needs to catch against the edge of the square hole (marked with the red arrows in the pictures)
First, bend the tab into a v-shape and place the whole cover into the remote control.
Mark where the steps are along the edge of the hole.
Cut where the marks are on both sides. Put the cover back in place and bend the rest of the tab so it is flush to the body of the remote.
Step 5: All Done
This took me about 15-20 minutes to make. I've been pretty happy since I get a fully functional remote control battery cover that's colour matched and free.
The cover for this example is a bit easier since it is a flat rectangle. I have successfully created remote control battery covers that are curved or have a bend to it. It took a bit more effort, but if you slowly trim the aluminum siding down to the right size, the process is mostly the same.
I hope this instructable helps! This is my first instructable so any comments or feedback is welcome.