Cad files are available here: http://www.thingiverse.com/thing:24315
Feel free to modify the design to fit your particular phone or car.
So, I bought a Galaxy Note recently. I’m not sure if you’re familiar with the Note, but in short, it is a Really Big Phone. Soon after, I bought it a sweet sweet wallet case, and it became Even Bigger. (Bigger, yet awesome, and now capable of holding my credit cards!)
This caused a bit of a problem in situations where I was used to having a more “standard-size” phone. Particularly, this became an issue while driving, as the phone no longer fit into the convenient cubbie in my car. I considered buying a car mount, but they were all slightly less than ideal in a number of ways, and to top it all off, would require me to take my phone in and out of its awesome wallet case multiple times per day. Oh, what’s a hacker to do?
Why, BUILD HER OWN CUSTOM CAR MOUNT, of course!
This device is intended to snugly fit a Galaxy Note phone in a Spigen wallet case. The back of the mount is custom-designed to fit in an empty compartment in my Hyundai Accent, and can be changed to fit whatever location you'd like. This design also features a hinge to enable the user to point the phone at either the driver or passenger, for radio or map usage.
This particular design is easiest to build with a laser cutter, but a jigsaw or other cutting apparatus would likely work just fine.
I recommend reading through the instructions before making any cuts to your material. Many parts of the design are variable and depend on your specific materials and setup.
Step 1: Pieces You Will Be Making
On top: Small half-circles fit into the horizontal slots in the acrylic rectangle and in the large wooden backpiece. Run the bolt through these to create the hinge.
V-shaped items show on either side of the backpiece are the prongs that pressure-fit into the cubbie in your car. They fit snugly into the vertical slots in the acrylic rectangle. (The acrylic rectangle is designed to fit inside a cubbie under the radio in my Hyundai Accent. You will likely need to re-size this piece to fit your particular car.)
J-shaped pieces stack on top of one another (later reinforced with glue and wood screws), and adhere to the bottom sides of the backpiece to provide support for the phone itself.
Note the two acrylic rounded rectangles at the center bottom. These were later changed to wood for aesthetic reasons.
Step 2: Requirements
Required tools: Laser cutter or jigsaw, c-clamps, acetone, wood glue, wood stain, wood screws, sandpaper, and sponges.
Required materials: wood or acrylic of your choice.
Step 3: Cut Pieces Specified in Cad Design Out in the Material of Your Choice
I used some ~eighth-inch scrap wood for the phone seat, and quarter-inch acrylic for the mount. (Note: All internal cuts are designed to fit these materials. Please adjust these to fit the material you are utilizing.) If you get any burn marks on your acrylic, Acetone works nicely to remove them.
Step 4: Assemble the Plastic Mount
Locate the two "prongs", the "car_back", and the "hinge_mount". These are the main components of the mount. When the device is installed, the car_back will be flush with the exterior of the car's compartment, with the prongs pressure-fit inside to hold the device in place. (Note: These pieces are custom-designed to fit a Hyundai Accent. You will likely require modifications.)
The prongs and hinge should fit snugly into the car_back, and can be held in place with SciGrip Acrylic Glue (16). On the opposing side of the car_back, glue the hinge snugly into place. (Note: I set the holes in my car_back off to the side to provide access to my car's volume controls. You may not need to do this, and may prefer to cut these holes in the certer of the car_back.)
Step 5: Assemble the Wooden Seat
The wooden legs stack up to make the sides of the seat. I used generic wood glue to fasten them together, and to fasten them to the back of the seat. Next, glue the legs_front pieces to the very top of the stacks. Set these with C-clamps to dry.
Step 6: Attach the Rest of the Hinge
The two "hinge_seat"s fit snugly into the back of the wooden seat, facing backwards. I used a long, thin bolt (+nut) to hold these pieces together with a loose fit, with a small rubber washer in between the acrylic pieces, to keep the device from swinging loosely.
Step 7: Reinforce the Wood
I drilled and counter-sinked (counter-sunk?) a few holes into the legs, and added half-inch wood screws as an extra reinforcement, as the "legs_front" pieces are essentially what are holding your (large and heavy) phone in place. It can't hurt, and they look quite nice.
Step 8: Finishing Touches
I added mahogany wood stain, to make my scheisty wood look a bit more like nice wood. I also considered laser-cutting sweet designs into the wood. You should! It would look awesome.