I was making a housing to record mini sprint races from the drivers view without ruining my $229.99 camera. So I took a trip down to the hardware store and picked up $20 worth of parts ($15 if I wouldn't have bought the safety glasses I didn't use.)
Step 1: Parts and Tools
1' of 2" schedule 40 PVC pipe
3 end caps (an extra in case you mess up)
1 Pair of safety glasses
Foam (the kind that goes around air conditioners, make sure there is no adhesive on it)
Flip Mino HD (I'm not sure if all the cameras are the same size but the Flip Mino HD is a VERY snug fit in the pipe)
Spray paint of your choice of color (I chose black because it matches the silicone I had on hand and my camera)
1" drill bit or any suitable tool for boring a 1" hole
A fish tank and/or a sink.
Step 2: Measure 1, 2, 3 Times.....THEN Drill.......
First, measure from the bottom of the camera to the middle of the lens (since the Mino HD doesn't have a very wide angle lens you don't have to be too terribly accurate when measuring). Mark it. Then grab your 1" drill bit and drill a hole where you would like the lens (you don't have much choice). After that, Dremel off the burrs and finish up the hole.
Step 3: Endcap Installation
Clean your pipe and the end cap, then apply the purple primer. After that apply a SMALL amount of glue to both the pipe and the cap. Apply firm pressure and twist 1/3 around until the cap seems to hold itself. DO NOT GLUE THE OTHER END CAP YET!!!
Step 4: Paint
After you let the glue dry for 5 minuets, feel free to spray paint the end cap and the housing.
Step 5: Cut.......again
Take those pesky safety glasses and throw em' out or just put them on a shelf (I threw mine out because I tried to use them as an the actual clear protector). DON'T throw away the plastic that they came in. I can't think of the type it is but it's clear, flexible (but returns to its formed position), and the PVC pipe cleaner frosts it so don't clean it off with that! Cut off a nice square of the plastic. It doesn't have to wrap around the housing but it has to be large enough to cover the hole and have some left over.
Step 6: Silicone
Take your caulk gun and apply a small layer around the hole. About 5-10 mm away from it. Then CAREFULLY place your plastic hole cover over the silicone and tape it with masking tape (that's what I did but I recommend you apply the tape to the lens BEFORE you place it on to avoid smearing).
Step 7: Wait
Let the silicone cure. While your waiting you can apply a small layer of silicone on the inside of the end cap that you didn't glue and let that cure too. This step is optional but necessary if you want it waterproof. Also, while your waiting cut some cubes out of the foam (about 2x2x2") you'll need about 5 cubes.
Step 8: Assemble
Carefully peel off the masking tape so you don't damage your sweet paint job. Clean the silicone off of the hole cover with your fingers and take a paper towel and clean your grubby fingerprints off of it.
Step 9: Test
Put the lid on your housing and submerge it in a sink filled with water and submerge it for 1 minute (just to be sure). After your minute is up, wipe off the housing to prevent water from getting in and giving you a false result and open er' up. If there's any water just add silicone where the leak is coming from. If it came from the lens protector simply peel it off and remove the silicone and re do that step.
Step 10: Install Camera
Place your camera into the housing and orient it so the lens is facing the protector or "window" then stuff in the foam cubes behind the camera and 1 on top of the camera then firmly install the end cap. After that your ready to shoot....or are you? I hope you remembered to press record before you installed your camera!
Step 11: USE!
After building regrets. First, I would have added a screw on cap to make it truly water tight. If the hardware store had Plexiglas I would have tried to soften it up with my hair dryer on steroids (A.K.A. a heat gun) and form it around the Pipe.