This is not going to be fully step by step guide but i'll go through the steps how i made the Ipod Touch mount quickly.
It's because it was about half year ago when i made it and i don't have enough video/ photo material to make fully step by step guide. Anyways i'll try to give you as much information as i can.
I made this mount mainly because i wanted to use GPS on my bicycle but i also found myself listening music while riding with my bike (but not too loudly so i still could hear the traffic well). The case works both in landscape and portrait, I also found out that when i removed the mount from my bike i could use it as a stand for watching movies or reading e-books for example.
I'm really happy with the final result and that's why i thought it's worth sharing.
The mount i made is usable with Ipod Touch 2G but it might work with 3G and some other version also. When you start making your own you should measure over the measurements just in case.
Step 1: Making Template
For a first i took a piece of paper and folded it around my Ipod to see about how big piece i need. I measured the length and width of my Ipod and drew the rectangle with these measurements to the paper. luckily i used squared paper so i still can show you the measurements i got (i'll include these on picture). So i made other measurements that were needed and cut out the template around the edges.
In case you have Solid Edge or some othe CAD software i also included the dft file of measurements drawing.
Step 2: Drawing Template on Copper
I used about 0,7mm thick copper plate and draw the shape of case on it using the template. I used the sharp metal "pencil" to draw on copper and i also used straight wooden stick to ensure the straight lines.
Step 3: Cutting the Copper Plate
I used metal scissors to cut out the outer edges of the case.
Step 4: Drilling the Holes
I put the lower part of case between two pieces of wood and used clamps to fix these together. It was needed to be done because otherwise it would have been really hard to drill the holes, as i did not had the drilling bench. I marked the places where i needed to drill the holes and used about 1mm smaller drill then the holes. I also drilled the hole for home button and volume rockers, but its not shown on pictures.
Step 5: Filing the Edges and Corners
I filed over all the holes and corners as shown on the measurements picture. I also filed the edges because they were a bit sharp after cutting.
Step 6: Sanding
When all the cuttings, drillings and filings were done i sanded the side of plate that was meant to go inside. I did it to clean up the area and also to make better surface for clue the leather on it. I didn't sand the outside of plate because i liked the ragged and old look it got.
Step 7: Cutting Out Leather
I found the piece of leather that was fairly thin and i put the plate i had cut on the leather piece. I cut out the leater about 10mm larger then template.
Step 8: Bending the Case
After cutting out the leather piece i started to fold the case. For this i used wooden stick that was about 8mm thin to put it between folding places. I secured the detail with clamps while working on it. The copper plate is soft enough to fold it with hands but i also used a rounded hammer a bit to make better corners. After bending the copper it gets stronger, so theres no worry that it would bend out while using it as a bicycle mount. To make the bottom of case rounded i used the rounded 8mm stick.
Step 9: Drilling Hole for Attachment
Before i clued the leather inside the case i drilled about 4mm hole in the middle of case to attach the mounting part on it. I also bended the hole outside the case so the nut head wouldn't stay on the way of Ipod. This had to be done fairly well cos otherwise if the nut would been even a bit on the way of Ipod it would have scratched the Ipod.
Step 10: Clue the Leather
You can't see the nut on that picture cos i made another case without the attachment but the rest is same. So i put the nut through the hole before i clued the leather piece on case. To clue the leather piece on case I used "Moment" clue and the same 8mm wooden sticks. Sticks were used to insure the leather to be well clued. Well i cut the wooden sticks so that they fit in the case densely and i rounded the endings of sticks to match the bottom of case. I put the softer side of leather outside, so it was better for Ipod. Finally i clued the leather and put the wooden stick inside the case and attached the detail with clamps. I let the thing to try about one hour before removing the wooden sticks.
Step 11: Cut Unneeded Leather Parts
After removing the sticks i used carpet knife to remove all leather from holes and edges.
Basically it was all done now and i jut had to attach the plastic bicycle attachment that i got from old bicycle light. If you don't have that kind of part you could make your own, be inspirational ;)