Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

pictures ?

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Im thinking of making holder (or backcover)to hold n900 on my mountain bike. Only think what`s keeping me back is, I don`t have touch probe to digitize n900 yet (I got promise, that should by one available in month or so).
If is there any chance you have digitized your one, and you are ok with sending my the model, I can start sooner.
I don`t have plans to make money from it, So in return I can send you back drawings/model of this holder.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Is a excelent idea to expand wifi reach and how about making some space in the back cover to posibly add the necesary wiring for the compass and the giroscopy to i2c bus? like it says in "n900 hardware hacking" then the n900 would be more than loaded to compete with any other smartphone/tablet.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I was thinking about the possibility to have engraved custom text/logo :) It's additional pass & tool change for machine, so I'm still not sure about feasibility of it.

Thanks a lot for Your kind words. Well, I wasn't assertive enough to open "pre-order" program - honestly, whole process of building CNC machine was done very slowly, as I've been buying parts only when got spare money + dividing it between few hardware projects ;) Now, as the machine is complete, same goes for backcover/full body project - I'm buying materials and tools (mainly, milling cutters as CNC tool bits) as money permits.

If You or other awesome people would really like to speed up development and trust me enough, pre-order sounds like good idea (next to traditional donations). I'm thinking about some special bonus for pre-ordering people - maybe custom engraved logo/text from first part of this post is appropriate here, as a special "thank You"? What do you think?

In any case, for people seriously interested in pre-ordering, PM me please. But, please consider, that it *is* going to need time before being available - maybe even few months. Of course, pre-money would shorten time much, but without unholy miracles. Also, I must take into accounts appearance of possible problems during actual manufacturing (can't predict everything, probably), so unexpected delays may (and probably will, considering Murphy's Law) occur.

WARNING, feature bloat ;)

Seriously though - full sized USB port inside cover would be doable, but without extending device length (*not* thickness, length!), it could be easily connected only via testpads beneath battery - as long as we don't want to force users into doing soldering under magnifying glass after buying body replacement(and we indeed *don't* want this ;) ). Ho ever, testpads approach doesn't have common mode choke - it isn't crucial feature of USB 2.0 (lacking this won't fry Your chip), but indeed useful for everyday high-speed use. So, while forcing USB port somewhere into body sounds trivial (*if* space permits it), no good way to connect it to N900 mainboard without soldering iron and microscope ;) Unless someone comes with ingenious idea, we must skip this one.

2.5 mm charging port got same restrains here - easy to implement inside body cover, no good way to connect it beside testpads. Utilizing those properly (to allow external charging port and/or additional USB port) would require some specially crafted testpads "module", with spring plates touching required pads, when body cover is assembled on mainboard. Doable, but would complicate whole design as hell, require crafting small and simple PCB circuit externally = increasing amount of work and money required, probably to 200$ or more for full body replacement, instead of 150$. I'm not sure if enough people would be interested in so hardcore implementation ;)

solarpanel - no way, maybe in version 70 ;)

:eek: I would be afraid that whole kickstand (default one, found in N900 backcover now) could break. But if it's working for You, why not? I think that, with enough "creative usage", new kickstand could be used this way too, despite being bigger and more stable.

I'll post photos of my machine in few days. As for prototypes, of course, when they're going to be ready ;)

My machine uses CAD and CAM, converted to gCodes. It's powered by LinuxCNC project (formerly called EMC2). It can use 3D models, if they're convertible to gCodes (via CAd or CAM again), preferably using FOSS programs. There is commercial software that can be used to convert (with better or worse effects) non-CNC compliant models into proper ones, yet, I'm dedicated to only FOSS usage in this project (not to mention, that, as usual, FOSS programs are working better in most cases, even in such specialized thing as CNC)

BTW, currently my machine operates @ 3 axises, which allows me to create backcover & full body replacement, if I change object mounting few times during worktime. Yet, my steep-driver support 4th Axis, which I'm planning to add in future (as axis used to rotate object, allowing full 3D shaping without re-mounting).

Aluminum stylus isn't good idea - it would scratch screen/screen protectors *very* fast, compared to plastic one. Of course, one can design aluminum stylus with plastic tip, yet, the latter sounds more like thing for 3D printer than CNC machine (much machine time/power and material needed to mill required shape of tip - it would result in overpriced stylus, 10$ or so, from top of my head ;) )

As for full body replacement & weight, as I've said it's going to come, and weight shouldn't be much different (little heavier, but nothing significant, not to be considered as a problem).

Would love to help, but I also doesn't have touch probe, designing everything by hand ;) (well, mouse...)

Well, that would require one to (somehow) solder compass/whatever to i2c buss. Extending body to have place for such thing would make N900 *really* bulky - but I see no problem for one to use version with big back cover, and put additional module instead of 2nd battery. There should be enough place for both module and wiring. Ho ever, I don't see any way to make enough space for both dual battery and some fancy module, at the same time keeping size sane :( Of course, epic modders could use other type of batteries (smaller) and make, for example, 2300 mAh dual battery & place for compass at the same time... But it's not directly related to body replacement.

[off-topic]BTW, haven't You though about using compass via bluetooth, in similar manner that N900's bluetooth wrist watch is created? AFAIK, You can put whatever You want, if it use i2c interface - including gas probes or whatnost[/off-topic]

@All
Really thank You for Your feedback and support! It overcame my wildest calculations for this project :)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I think what you have done so far Estel is awesome in itself. DIY build of a CNC miller - Wow! I trained on them back in the 80s (never touched one since though).

Would be extremely interested in a post (off topic, natch) of the machine project.

Also very interested in what you are proposing for the N900. A replacement back cover with an improved kickstand would be really great. A full alu reshell would be gorgeous, but I fear it would be out of my price range, though.

Have you considered developing a case for the Raspberry Pi as well - I think there may be a market there!

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Interested in a large version for dual battery. If it could also feature the 2.5mm charging connector to spare the USB port would be totally awesome.

If you can't have the nice springs to connect to the test pads, I'd be fine with wires that can be soldered. In fact, it could be even better- easier for you and easier for the modders.

BTW, another idea: what about recessed conducting pads, like on dect phones cradles?

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I like a lot of the suggestions being posted here but what I really would like is to be holding the same device I am now but just sexier. It simply doesn't need anything else. Can you get around the stylus slot with your machine? And to make it complete, would it be possible to include a screen bezel aswell with MAEMO instead of N***A etched on it?

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Once we receive this thing, how much expertise will it take to actually install it? If much, I suggest you add on an optional installation fee for those who don't want to mess with it, we send our device(s) to you or someone you appoint, who does the installation and sends it back.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I'm assuming the full body one will need a teardown to the system board.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Think he was suggesting that you have 4 little tiny bumps on the surface, one protruding up from back surface near each corner.

The bumps would be like the little rubber feet you see on laptops to lift the back off the surface it is sitting on.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I just got confirmation email, from Farnell, that my Raspberry Pi will be delivered end of june, first thing what I want do with it is design/make a case ;)

Estel: I wish you luck with your project, as you were saing, you dont have a touch probe to digitize N900. For me this is unimaginable, because all of the small(function) surfaces n900 case have.

/sorry for my english, just woke up ;) /

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Attachment 26047

Attachment 26048

Attachment 26049

Attachment 26050

Pre-Pre-Pre Sample Design for New N900 including Kick-stand , backcover sample Text & four dot's :)

C h e e r ' s :)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

im in ! The fat cover, please.
Thanks Estel.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Excellent mockup....I'll take 2!....

:)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Yea, I thought about that one too - waiting for my Raspberry Pi to arrive, as I like to have "real thing" to design on (there are schematics for RPi including dimensions, but it's not the same thing as holding one in hand).

In full body replacement, there will be a place for stylus surely. As for screen bezel, maybe in future, but for now I don't plan to touch screen part at all (whole slided out screen part remain original, as it's made of metal already, and replacing parts around screen are much less trivial, both for me as design part, and for end users during replacement).

Not much harder than disassembling and assembling N900 now, of course only mainframe parts. From my experience, it's one of easiest devices to open&close - hardest part is putting screen tape on place again, due to limited space (but still doable, even for beginners).

Of course, possibility of sending device to me, assembling and re-sending back will be there - probably for free or for very small amount of money (5$ or so), but I don't expect much interest in that - shipping prices to me and back would be overkill, probably, for most people, and assembling personally isn't really that hard.

Of course, all of this apply to full body replacement - (BTW, I would like to remind again, that it's going to arrive some time (up to few months) after backcover(s) - I want to start with something less complicated) backcover should be as trivial to install, as default/mugen one is now.

@immi.shk
thanks for mockups :) Yet, I must confess, that it's going to look slightly different, not only about colors ;) No chances for 4 "micro-legs", as it would require milling out all surface *deeper* than they are - huge material and time waste - but it should be pleasant to touch due to sanded surface, and good to stay thanks to kick-stand leg.

/Estel

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Definitely interested. As of now, more interested in the single battery (standard) cover but I could be persuaded to go dual scud.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

At the risk of adding to creeping-featuritis, would that idea be a goer to incorporate a Powermat receiver?

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Not for a few first versions, definitely ;)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Just to clear things up for me... Estel, are you talking about making a protective case for the N900, like in the mockups above, or are you talking about a replacement for the N900's standard body, i.e. the plastic frame between display and backcover?

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Replacement body (as 2nd project) and backcover replacement (as first thing to appear).

BTW, I think that on the mockups above, it's also replacement body - despite, that it's looking a little like "tank" :) Also, be aware, that those are *not* my mockups.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Been following this thread.I dont have a N900, but I do support this kind of community ideas. If you include a donation button, I will surely give some. And who knows, maybe the N9 could get the same treatment? :)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I was thinking about drFrost's 2.5mm charger solution that charges the battery directly, so no need for micro-soldering, just two loose contacts to connect to dual battery mod.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Might I suggest rather than an acid dip, actually anodizing the aluminum? This would give it a very tough finish that would really add to the look (and prevent oxidation to boot). As a nice side-effect, you can provide a range of colors (based on what your local anodizer shop can do).
Gloss black would be nice, but so would an intense, brilliant blue. :D

As to the texturing, I'm guessing that by sanding, you're going for the "brushed aluminum" or "spun aluminum) texture. Another possibility for a nice grippy texture is a quick hit with a course sandblaster.

Also, for something like this that it sounds like you're going to be milling very thin (to keep it light), I'd suggest using "aircraft" aluminum - 7075-T6. IIRC, it's roughly double the tensile-strength of "marine" aluminum (6063-T6).

I miss working in a machine-shop... it's been over 2 decades. :(

I, too, am very interested in your homebuilt mill. :) I hope you took lots of pictures and video of the build process!

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I too would be very interested in 3 standard size covers.
Like to see some ideas on how they will look first.

Case for a Pi sounds good too, when I get my hands on one!

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

for the 4 "micro-legs", would it be possible to use rubber that would be glued in 4 "holes" or something?
the current plastic (back) cover is not too scratchy on other surfaces, but an aluminium one could benefit from four rubber legs giving it more grip on slippery surfaces...

(pity Estel still has me on ignore :rolleyes:
also odd that he should not like UK_Bill; after all, they both are hardware guys :D)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Hm, I see. Generally, it's very specific feature, only needed for few people, but on the other hand, modder in me understand You very well... Probably, it's going to end up being offered as custom option. It's much less hassle to find place for such port in design, which I cannot say about full-size USB port ;) Of course it adds some work and additional part etc, but not too much - I think that additional 5$ for this special feature is ok, if - during tests - I"ll confirm that there is actually enough place for another hole and construction is still solid :)

Here another thing comes to my mind - people interested in "flat", i.e. single battery version - You all realize that there is no place for tripod mounting point, so only improved kickstand and camera lens cover can get up into flat design?

Thanks a lot for You very constructive advices! Will surely keep them in mind. As for acid dip vs anodizing, yea, I though about that. + for acid dip is that I can do it it home, no matter how it sounds ;) for anodizing, I would need to use anodizer shop as You suggested, which would, probably increase price tag (most of them require to pay quite a high price for anodizing small things, at least where I live :/ ). I'll check possibilities after milling first prototype, and report back. BTW, IIRC, acid dip also gives it protective cover - of course, much less resistant than anodizer, but still much better than plastic thing we have already, or bare aluminum ;)

/Estel

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

It's like the n900 is going to be reborn again after Nokia ditched us it gets new software from cssu and gets external treatment now wow long live the Nokia n900 so proud I own one.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Considering the depth due to the camera lens and the fact that the rear camera is seldom used when charging, what about using this recess to "fit in" 4 contacts - one on each side of the cube ?

It should be more resistant that the little 2.5mm barrel connector and ease the constuction of cradles or other charging options that could use that to firmly hold the n900 in place.

The 4 contacts could also be used in 2 different configuration : either for charging (2 contacts) or for USB (all + ground)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Crazy, but interesting idea. I'll think about that (read: Will check how much possible is to design it for CNC hassle-free). Don't get high hopes though, as putting any custom, isolated contacts/paths in already conductive (aluminum) cover isn't going to be hassle-free, probably. It's much easier to put pre-sold, standard 2.5 plug, than design&make contact boundled inside "camera hole" (if we're talking about the same thing - hole, that sits in 2-battery variant of backcover, due to camera being deeper than cover surface).

Still, I'll check possibilities.

/Estel

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Since we are talking about big cover with space for two batteries I assume that all buyers will get their hands dirty with soldering iron to create dual battery so soldering 2 more cables would be trivial. Thus I don't think it's so specific a feature.

Sorry for pushing it shamelessly (I do know how it is to try to make something and have everybody pushing his idea of awesomeness) but seeing that usb failure is the No1 cause of death and warranties finish by the day now, I think it's a must to try to keep the remaining N900's alive and kicking.

Edit: even simpler would be to just create a placeholder in the inside for a 2.5mm jack from e.g. the N8 (specific part, easy to find and with known size) and create a small internal recess where the hole should be so that dremelling the hole will be easy.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Generally it's good idea. dr_frost_dk's charging port connected to battery isn't bad thing, yet, it have some limitations. First of all, it can be charged only by Li-Ion charger of any kind (not power supply). Second, and more important thing, that it should *never* be left charging to 100% during device runtime - power used by device fools Li-Ion charger, which keeps charging battery more than needed = unhealthy for battery life. Last and least important thing, is that bypassing N900's charging circuit confuses bq27x00 chip, so no way for reading 100% accurate (after proper calibration) battery SoC readings (voltage-based reads can be great, but will be never even close-to being such accurate as chip measures).

On the other hand, using port other than semi-fragile USB got obvious benefits. Considering this, I'm more and more tempted to create some crazy solution for full body replacement, that would mean having external charging port connected to testpads. This way, we would have best of both worlds - charging by any 5V power source, without touching USB port, yet still processed by N900 charging circuit.

I can't promise anything, but I'll check what is possible - in meantime, could someone - fluent in reading N900's PCB schematics - check, if for 100%, testpads +5V and mass comes through same safety elements as USB charging? I'm sure about USB data lacking only common-mode choke, but about power lines, it's unverified info for now.

/Estel

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

If the test pads (5V) does not have protection then adding a small fuse to the 2.5mm plug base should not be a problem.

As for my system, it is sufficient for me since i have 20+ 4.2V sources/power supply's, else a 5V - 4.2V (with charge controller) chip does not take up much space, i have many laying around from the EGO-T E-Cigs i order home for people, they come with an actual LiPo/ION charger that takes 5V 400mA (USB 1/2 Limit) and have an indicator light to show when battery is at 4.2V, but this is just an example.

But having another method of charging is still very good, i on average use my USB one time a week MAX.

I have been thinking of upgrading my setup with some copper lanes (flat copper...) in the top of the cover to the 2.5mm and then some lanes on top of the battery, so when the cover is on the battery is connected to the 2.5mm, this is just to eliminate the wires that attaches my Dual Scud to my cover

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I have two words for you: Inductive charging.

Contact plates always wear, or get grimy, or what not.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Yes i know, but i just can't find the time for anything lately, still have an 4x TDA7293 amp that is only begun, gotta get going on making an E-Bike with my homemade electric motor, gotta fix our car etc...

Would be nice with an inductive charging pad, but the cheapo DX charger system is still working just nicely.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Oooh, +1!!! :)

Still got an old Palm Pre including touchstone here and it's still on my TODO to attempt this: http://talk.maemo.org/showthread.php?t=56950
Would be great if that could be an option for the custom cover, too. ;)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I'll buy a full body replacement (+ thin battery cover) once it becomes available, for sure.

Also: I have no need for any of the extras mentioned by some.
I, and I'm certain I'm not alone, only want a simple (slightly improved) aluminium replacement of the standard N900 housing (basically, your original plan without any interference from anyone else). Just something to keep in mind.

Thank you for your support of the Maemo community, Estel.
Surely you only offer us this option because it is the hobby you enjoy and you want to take your self-built baby for a spin, but it's efforts like these which remind of why I'm still using a magnificent, though dated device from late 2009 in 2012 - a significant reason for that, is the beautiful community that is powering the beast.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

A LiIon charger circuit from 5v/1a (USB) to 4.2v costs around $4, delivered : http://cgi.ebay.com/universal-1A-lit...item35ba49263b

If you go the direct battery route, it is cheap enough and small enough that it might be included in the replacement cover to use direct USB power from a desktop computer to charge the battery by the jack bypass.

Regarding leakage causing overcharge and SoC confusion, these are real problems. A good solution would probably require a circuit sitting between the battery and the n900, to be able to take that leakage into account.

I'm not good in electronics- I don't even know how it could be done. Maybe someone with a good knowledge of charging circuits could help.

Right on. No need for external circuits.

Regarding the USB test pads having all ESD protection (etc.) but missing coils, according to http://electronics.stackexchange.com...-needed-on-usb such coils are only needed for EMI, so yes they should not really be needed - or they could be easily added by modders who would absolutely require them for FCC compliance :-)

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

Anychance you could CNC a more solid metal USB door for us N9 users?

The current one bends and breaks too friggin easily!

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

I am not fluent with the PCB schematics but I have them open and trying to figure out.

About USB testpads, do you have informations not present in the schematics ? On page 4 testpad J5300 and J5301 (USB D+/D- seems to be *before* ESD protection.

Regarding +5v, J2061 which is usually identified as 5v in the pictures is nowhere to be found on the schematics.

I guess I will have to follow the traces on a scan of the PCB - this may be where you have checked D+ and D-? (but I don't know how to "connect" the 2 sides to follow J2061)

BTW It was reported the 2A fuse is missing from 5V but I have not checked that yet - http://talk.maemo.org/showpost.php?p...6&postcount=74

EDIT: Also, if using J2061, a switch or an optocoupler for D+/D- might be needed so that the N900 enters charging mode, as indicated in http://talk.maemo.org/showthread.php?t=72753

I'm thinking of a simpler solution : a Reed switch, and leaving a magnet when the N900 is charging.

Re: [Pre-Pre-Pre Announce]Black Aluminium replacement body & backcover for N900
 

man i have a cnc roland modela i may help you here in egypt and send you part of the money ,btw it will be needed here we have a lots of broken n900s
my exams will be over at 4/7