Since i was going to make another car Dock for my truck and been trolling this site for years , I Thought this would be Great for my First Instructable . Using Multiple Adhesive Compounds , Zap a Gap / Zip Kicker (Cyanoacrylate) , 2 mix Epoxy Hardner, Paint safe Tape , epoxy based Paint adhesive for Flocking Fibers .
and since cellphone kits are expensive , bulky and uglier than my neighbors face i had always opted to make them myself .
since the inception of the Nokia 6110 in 97 and being I've had at the least eight cell phones since then and bought my truck in 2001 , everyone of those phones I've made a Docking for them every one of them more elaborate than the next . actually the first two phones had a charging cable ,
So after Clearing space on my bench ,Gathering all the materials needed , taking a drive to the Hobby Shop for some Zap a Gap ,
start cutting the ABS ,going to 711 for a Super Gulp come back glue the Materials together ,eat some lunch come back fit the phone in the mold letting the Filler set , I used this time to go to the Market , make & Eat Dinner .
come back and sand and shape and add more filler sand and sand flock the the Dock go get a refill for the Super Gulp , mount to the car , I was done and had fun in the Process , one days work about 10 hours or so , and about $4.50 for the zip kick super glue , all the other stuff i had in my garage
So i Hope My Steps are Informative I've Been Fabricating Stuff Like This for 20 years or so in the Car Audio Field ,I'm Not saying where but where i worked we have been featured in a lot of magazines mini truckin , Car Audio& Electronics , Installation news , low rider even a few others i cant remember for the life of me , So Be Nice In your Comments, This is My First Instructable and maybe not my Last :) Thanks
Step 1: Materials
Step 2: Last Call Out
HTC G2 Cell Phone , or Whatever you may have !! Any brand of paint safe , easy release masking tape , Blue 3M is Probably the best , this is 3M as well
Step 3: Can You Hear Me Now ?
Use the Tape to completely cover your Phone tape shapes pretty good to get a good fit,
add about five strips of tape to one side of phone to allow for spacing ,so its not to tight , you will be adding flocking material, also,the tape protects it from the elements in the shop and to gap the areas when filling the epoxy
Step 4: Cutting Materials
cutting the desired pieces with a bench top band saw to cut the 1/8 ABS Plastic
Step 5: Is It Straight ?
i used these heavy marble bookends for stuff like this something flat with a straight angle
Step 6: Crazyyyy Glue !
Step 7: Ready to Test Fit
Step 8: Snug As a Bug
ok now it fits great ,gaps on the side are good , size is good . snug fit
Step 9: Just Take a Lil Off the Side Please
shaping the straight edges , sanding on the flat surface using 40grit sandpaper i think from a planer sander ? nice straight angles
Part A is the Filler , Part B is the Hardener (Sorry for the blurry pics)
Step 11: Stirring the Pot
Mixing the two part epoxy filler not too much , just a bit more of hardener
Step 12: Let It Rest , Dinner Time
as soon as you slather it in the corners , slide the phone in and let the molding process set in , i used this time to go to the store for dinner , make and eat dinner ( oh i forgot ,to free the taped phone you can spray the taped phone with silicone spray or can put some vaseline as well but lighly coat it with a towel
refreshed and full from dinner , peel back the tape and carefully remove your phone from the mold
relesed from the mold you have a depth of the phones impression , you can see where you can cut the corners
Step 15: San Do Floor
i use 80 grit sand paper from a DA sander for a more delicate sanding of edges
now you fill the edges blindly and use the phones impression to add filler in the sides , i didnt show that i used the band saw to take about a 1/4" of the bottom corners, and using a ball grinding tip for the dremel to grind the filler flush with the impression the phone made
Step 17: Looking Good , Time for a Break
Gaps are great ! sides are nice and thin corners and edges are shaped evenly all by hand .
Step 18: More Cutting
now you want to cut out for the Charging inlet , for this i used a dremel .
Step 19: More Grinding
on the back i added 1/4" = 2x 1/8" spacer of ABS
grinded down the ABS with the dremel again and filled the edges with the epoxy filler . ABS is wet sanded for a smooth finish ready for the flocking glue . lol
Step 21: Get the Flock Out of Here
this is a Suede Flocking Kit , by The Install Bay @ http://www.theinstallbay.com from a line of Awesome Custom Products Endorsed by David "Fishman" Rivera
Step 22: Oooooooooooooo
oooooooohhhh SUEDE !!!!!
counter sinking a 6mm thread screw
Step 24: 90% Done
attaching the screw to a universal cell adapter from motorola hands free kits , even the 1 1/2 " X 2" bases will work as well , the spacer on the back can accomodate it That is one half of the adapter .
trimmed out a piece of ABS , to cover the plug hole
knotched it for the 3.5 Aux cable with the dremel .
backing retainer plate screwed in
Step 31: Mounted
after relocating the emergency light switch to the left of the steering wheel next to the dimmer switch , the dock is now mounted and free from the dash overhang , and a thin piece of real suede liner to cover the screw .
Step 34: Finished Just in Time , Just Got a Text From the Wife
Final Result Sleek Smooth Suede Finish , firmly Mounted , it sits at a 78.6 deg angle, the weight of the phone sits firmly in the dock , and since i use a 3.5 to rca adapter for audio and hands free capability , plugged into the AUX of my Stereo and the 3.5 jack also will keep the phone down ,