[Touch HD Accessories] 2'NixorNot2'Nix:
Hi All

When I looked around for a bike and car mount for my Touch HD I wasn't very happy with what was available.

Specifically I wanted a 'protective' mount that would keep the phone dry and dirt/mud free, I also wanted to be able to leave the phone in the unit and step away without someone being able to grab the phone easily (I realise if someone wants to steal it they'll do it, however I want to at least slow them down if they try).

After searching I found the Ram Mount AQ3. It seemed perfect as it had a clear cover and was lockable, however it was 2mm too narrow to fit the phone.

Dremel time.

http://www.ram-mount-uk.com/ram-hol-aq3.htm

To achieve the following you need about an hour of time, a Dremel with standard fittings, a steady hand and a bit of concentration. If you've not used a dremel on plastic before I'd suggest practising on other tough plastic to get an idea of how the dremel reacts before going to work on your RAM Mount.

Please follow all the standard safety precautions using your Dremel, it's not my fault if you cut off your finger or an exploding bit blinds you.

The plan was to increase the internal width of the mount by about 1mm on each side and to have a cutaway that would allow a mini usb connector to fit the phone while it is in the mount.

IMPORTANT NOTE

Do NOT use the Dremel on a high speed setting, this generates heat and causes melting rather then the grinding you need. I used my Dremel on the lowest speed setting and constantly moved the area being worked on, after about 2-3 minutes on a 'side' I'd change to the other side to ensure the plastic didn't get heat buildup that would cause melting.

I decided to use a Dremel grinding tip to achieve my objective, specifically...

http://www.dremel.com/en-us/AttachmentsAndAccessories/Pages/AttachmentsDetail.aspx?pid=932

Make sure the Ram Mount is securely positioned and that you have good access to allow you to work across both the internal sides you want to grind. TAKE YOUR TIME.

You want the whole side of the Dremel bit to be in contact with the plastic, try to avoid angling the bit as you'll find that either just the top edge or bottom edge of the bit will be grinding the plastic.

Working in a smooth consistent way start to grind the internal area of the mount on one side, work gently from side to side on the area and do not stay on one part too long, heat buildup and melting happen surprising quickly and plastic will not grind if it's melting. Do not press down on the plastic too hard, let the bit do the work for you.

After working both sides say 5 times get a vacuum cleaner and remove all the ground residue that is in the area, use your finger to rub the internal areas to remove any small particles and vacuum thoroughly again.

Install the two thin padding sheets supplied with the mount and then install the phone.

Test to see if your phone now fits flush, if not try to identify the areas where you need extra grinding and rework them, try to ensure you remove equal amounts from both sides of the Mount. Always vacuum before trying to mount the phone, the dust grinding produces is extremely small and could get inside your phone if you're not careful.

When you're satisfied with the flush fit you then have to remove some extra plastic from the area near the volume buttons, with the phone fitted visually identify the top and bottom position where the buttons sit and spend maybe 2 minutes further grinding that area. Vacuum and install the phone to ensure the buttons are not pressed when the phone is fitted, repeat till you're happy.

You should now be able to mount your phone, fit the clear plastic cover and close and lock the lid, this should all be possible without the volume buttons reacting inside the case.

If you've got here well done, the next step is fairly straightforward.

With the phone fitted identify where the mini usb connector is on the phone, mark or score the plastic at both ends of the connector, remove the phone from the mount.

Using the following cut off wheel cut into the mount at the previous two marks.

http://www.dremel.com/en-us/AttachmentsAndAccessories/Pages/AttachmentsDetail.aspx?pid=409

Again be careful using the cutting tool, the plastic will heat up and melt quite quickly.

Once you've cut down into the plastic on both the marks then cut at a 45 degree angle into the plastic that's going to be removed, you want to cut a V shape within the marks. Using the cutting tool keep working to remove blocks of plastic within the marks until you can mount your phone and connect a mini usb connector.

That's it, you should now have a secure lockable box that your Touch HD fits in perfectly.

Good Luck

Sorry about the photo quality, my flash camera is elsewhere at the moment.....If people are interested I'll take detailed photo's next week.

Case Closed

Case Closed with Cover in Place

Mini USB Cable attached