[HD2 Accessories] osrix:
So here it is! (Pics below!)

After a couple of days of refinement I am quite proud to share my Defender extended battery mod :D

The reasons for doing this are obvious enough I guess...I love my Defender but i also want maximum battery power! so after some time wondering if i dare do it, I went for it and I'm pleased with the results.

I decided early on, that with the Defender backing in place there is little need for another backing inside as long as the extension part is not too big the battery should be held in place quite nicely.

Firstly here is what i used for the Mod:

http://www.superetrader.co.uk/htc-hd2-extended-battery-2400mah-high-csht8585xl-p-11745.html

I used this battery, firstly cos its cheap but secondly because i think its a little thinner than the official one (could be wrong, mostly the cheap part:)) the battery is suprisingly good quality but the cover that came with it didnt even fit properly to start with so i didnt mind cutting it up.

A Dremel with a circular saw blade

Milliput Epoxy putty

Super Glue

Polyurathane sealant

Epoxy Rapid set glue

I wish i had taken step by step photos for you guys but I was so busy trying Not to screw up my case beyond repair i only thought of it afterwards!

Method

First of all the use the battery to mark out the hole in the back of the case,

Then using the dremel cut the hole :eek: going to the outside of the line to give about 1mm clearance all round.

The next step is to modify the cover that came with my battery , this whole process was a little fiddly and takes some careful measuring...basically it needs to fit the hole I just made; cut one end down to the same length and then put the defender backing on with the new battery installed to get the height of the of the battery that is now poking out!

So with some cutting and sanding get the cover to the right size, and glue onto the case (with the open end at the camera lens end) with the super glue.

Now on the inside is where i applied the epoxy putty, maybe its not esencial but I figured it added some strength.

You will need to cut a small additional strip for the open end ...its easier tocut a small strip slightly taller than is needed then trim it down after it has been glued into place. Fill any gaps from the inside with putty.

Carefully measure the new hump and then cut the rubber of the defender backing to fit as closly as possible around it.

Once happy with all this CHECK the back now fits on with the battery in place before going any further!

If it fits ok and your happy mix up a small amount of epoxy glue and very carefully apply to the outside; where the hump meets the back and apply a small fillet around all the edges this is gonna make the whole thing much stronger than just using superglue.

The next thing I did was to glue the offcut of rubber backing onto the new hump, I guess this is optional but i figured it would give the finished piece a more pro look :)

Anyway, after a couple of days I decided to use the polyurathane sealer to seal it all up round the edge and to stop the rubber peeling...

So here are the pics: again sorry i didnt take any step-by-step's, hope you like it cos I do.:D

The last 2 pics are the Final.