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

Thanks a lot, somehow I missed your 1st post.

As for GSM, yes, I've done tests - in city areas there is 0 difference, in rural area with only one strong Node B signal is a little weaker if we face it *directly* with the alu backcover, and a similar *increase* in signal strength when we face it rotated 180 degrees (i.e. with alu backcover positioned like "reflector" behind N900 internals). None seemed to change anything in practice.

I have booked (and payed) more professional signal ratio tests for body replacement phase, when it will be ready for such tests.
---

As for scanning N900's body, it would surely help a lot. As I've said earlier in this thread in answers to PEB's similar query (sadly, he never managed to finish that 3D scanning job), plain STL file format would do best - it should be least problematic for you to obtain and for me to work on (STL is supported by most FOSS CAD programs, and, more importantly, it is only one format for 3D with really good support in FOSS CAM g-code converters).

There is absolutely no problem with every part being scanned as separate file - of course, if you have skills and time it would be even better to have everything combined + separate files as addition, but, as I don't have access for 3D scanner, I'll accept basically whatever you may throw at me ;)

Thanks again,
/Estel

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

Estel,

do you know if it is possible to remove/detach the keyboard from motherboard? I want to design a body where keyboard is at the same level and below the screen to make the device thinner. Like referenced somewhere in the beginning of this thread.

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

the keyboard "buttons" are part of the motherboard, it is not detachable

are you thinking of making one without the slide?
you could loose a little thickness by removeing that mech from it but not enough to bring it to the same level

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

Yep, exactly that. But I also figured that it wont be enough to bring to same level. How close would it be? 2 mm?

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

You can (easily) remove white plastic layer (the one, that have metallic parts, bending on press), but buttons pads are on PCB. Only one way to make keyboard the same level as screen is to use very thick button layer (the one with letters and numbers printed on it), *or*, even harder, using something thicker as replacement for white layer.
---

BTW, how scanning goes? Have you evaluated possibility of doing it?

/Estel

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

It's really hard, domesheet with light guide, like the one in N900, is patented by Nokia, so you would have to say goodbye to keyboard illumination.

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

Haven't started yet. Was sick the last few days. Going tomorrow or friday to the lab to ask for scanning procedure.
Problem is also, this N900 is my only, main phone. So if something goes wrong, I have no backup phone. Hope to find a cheap n900 for parts.

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

Good news - I've changed my 16 kb/s ISP for a cellular 512 kb/s (albeit unlimited), so I'm no longer in late 80's network speed. It meant that I'll be able to upload more photos. As today, I've finished setting up all bits of machine in the new "workshop", I'm starting milling camera cover rev. 3.

If nothing goes wrong (tm), you may expect some real eye candy late this week :)

/Estel

If I ordered the whole case replacement, would you be rolling out the back cover first? And will it ship?

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

As announced earlier, backcover-only thing is going to roll out first, followed by whole body replacement. Could you, please, specify what you mean by "will it ship"? Shipping costs are not included in pre-order price (as it depends in your location), if that is what you're asking. Of course, every supporter is made aware of that, before pre-ordering (in addition to stating it few times in this thread).

Belive it or not, but I'm doing it on minimal-to-non-existent profit, and I didn't wanted to round-up pre-order price, just to compensate for most-expensive shipping fee scenario. So, when it's ready for shipping, I'll contant pre-order supporters about their preffered way of shipping.

/Estel

// Edit
After rolling out backcover-onlhy phase, I'll contant moderators about changing thread title (getting rid of "pre-" parts) and I'll modify first post, filling it with proper annoucement data.

I mean as in the whole body replacement includes the backcover right? So the backcover from the body replacement would be shipped first? Or the whole body including the backcover ships at the same time? Thanks.

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

Of course full body replacement project includes it's own backcover. *But*, it is not the *same* backcover as proposed separately - they're both feature equivalent, but standalone backcover won't be usable with body replacement's one and vice-versa.

Standalone backcover is made to fit into standard N900's body.

Body replacement will contain different clipping mechanism, as well as changes required for radio's to work on full-alu body. Also, making room for body repl. features require re-working parts of case backside - it's simply impossible to keep original clipping, there is too much "wasted" space in original body.

Just for the record, it was stated earlier in this thread (no fingers pointed, I realize it may be hard to find such details before OP edit).

/Estel

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

A little status update - "release candidate" for backcover went to anodizing shop. It means that I've milled a feature-complete backcover, which, if no problems found, will be the same as one released soon :)

I had someone to help me during last prototype milling, so I grabbed N900 and helper person took extensive photo-session of whole process, from alu brick, to ready unit.

I planned to create a photo-log and post it here, but, guess what - it turned out that unit I grabbek is one with modified camera module (for InfraRed prohotography), the one which I haven't had time to finish fixing. So, All 14 photos are pinkty, blurry, and overall crap quality :rolleyes:

I'll fix that, while milling another proto unit - meanwhile, friend at anodizing shop will take some more professional-looking photographies of ready unit, which I hope to post here soon.

/Estel

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

A perfect example of being "hoisted by your own petard" transl.: blown up by your own bomb.

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

Where are you located, I am willing to send you one of mine temporarily for you to scan.

Will it be a problem that I have springs jammed under the EMF shielding on the GSM chips? The typical "telephony functions disabled" error kludge-fix? (I can take them out, but the shield itself will probably has slight distortions in it.

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

Me, I'd just upload all of the bad pictures somewhere for people to look at if they really wanted to. *Shrug*

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

I recently moved to Nokia 808 for my main main phone. So now I am able to use use my own N900 for the scanning. Thanks for the offer though. I will had to the lab this week.

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

I'd like to get more information about pre-ordering. I'm a little bit on the fence because I use a sliding silicone soft cover, and I like the little bit of shock resistance and the fact that it's raised around the screen as a sort of a bumper, but particularly if the added thickness on the neo900 makes those fit too tight anyhow (although I kind of suspect it won't), this project seems like the next best thing. Or possibly a better thing.

If it's designed for dual-battery setups, would a single battery rattle around?

Will the "Fallout" version scratch significantly more easily than if it were anodized? If so, and if different color anodizing options are shaping up to be a reality...what about clear anodizing? (Sorry if that was asked already.)

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

Hi, first of all, thank you for the great effort you are doing.

I always think of an metal housing for the N900 like the OEM one, slim, no extra battery and chrome black.
First you have to imitate the original case and then move on from there, i think you posted some real photos of a prototipo but they are down, can you upload them again? thanks!

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

it's been a bit quiet here, any exciting update posted?

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

Not that I want to speak for Estel, but I asked him about situation recently, and he said he's been trying out different anodizing shops. Apparently the first one wasn't up to the level of quality he was hoping for, so he's been trying others, some of which seem to be too expensive at the volume likely to be made. As I understood it he's waiting on a few more anodizing shops to send back samples, and then he'll update with pictures. Hopefully I didn't misremember anything.

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

Been almost 2 months without update. BUMP.

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

Sorry for the dela, guys. I got some nice (and quite extensive) photo-diary of producing backcover and current state of things made with proper photo equipment, finally - I'll set it up here after recovering from serious lung's illness that I'm passing right now.

Thanks for patience,
/Estel

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

Awh estel, get well soon!

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

Quick question: the Neo900 board will need a spacer frame and enlargement of the charger hole to fit into the N900's body. Would it be possible for you to make back covers that take this into account?

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

I was thinking of application to Neo900, just never made a statement here. So, yeah, if possible would it be done?

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

+1 for this.

If were to spend that much for the neo900, I'd rather it were in one of your bespoke and engraved original cases. 100% unique.

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

Considering, that Neo900 is going to - after all - be compatible with N900's case, I plan to support it since day zero ;) Someone who want to remain anonymous from Neo900 team promised to give me access to Neo900 board for a few days, as soon as it becomes available in final form - for real life tests. I should, also, get direct and precise data on charging hole's size differencies long before - to evaluate possible "compromise" of making size that doesn't look ugly on N900 but works for Neo900, or need to change this details for declared Neo900 orders.

As for backcovers, there should be 0 problems (but, also, 0 possibility to kill need for a spacer, AIUI). The only affected thing is full body repl. - this one will surely still require spacer at first, but it shouldn't be hard to change this detail too in Neo900's "fork".

Also, there should be zero problem with milling the spacer itself from material matching the case... Which, BTW, can include possibilities for decorative touches - like, different finish or color for the spacer, or even totally different material type - spacer made from black oak wood paired with black alu body, anyone? The above is just an idea - no tests on how it would look actually, but since first hearing about necessarity for a spacer, I thought about making it a visual "feat", instead of hindrance.

/Estel

Ps.
While I'm writing already, might as well throw in what I'm working on ATM (using the time I need to spend in bed/home) - following idea of invaluable Mentalist Traceur (ok, to be 100% honest, I planned to do it at "some point" anyway, but recent conversation with him positively pushed me to actually make the "some point" a more foreseable one), I'm going to place all project's files on some Git. Tediously cleaning them up now, for making it better readable for other people ;)

When ready, It should allow to print preview models on 3D printers (after converting LinuxCNC g-code to one applicable for printers) if you happen to have access to one, or even contribute to final look of project by forking, optimising my cheesy g-code lines ;) and requesting pull. Free and Open Source Hardware, FFS!

/Estel

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

Hellas Estel, since the Neo900 project is plausibly moving forward is there some update on the aluminium full body replacement for N900 also including the changes for the Neo900? I am asking since I'd love to get the full body replacement for my Rover, but dunno if I will be able to use it on the Neo900? Can you please share what is the situation/plan? Thank You, Beau.

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

Can you please post high res. photo's of the newest proto to asses the finished quality of material, build quality?
Not to hurt someones feeling, I understand how difficult (and awsome :-) ) a project such as yours is, building a milling machine from scratch. But the 3d printed keyboard OH for Jolla looks really cheap quality. I am sure milled alu looks much better than that?

What is the weight of the alu body/ cover? How much heavier is it compared to stock N900?

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

Hi Estel, what do you think about this?

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

To give up camera cover and backstand? What for, similarity to Lumia?
Also two Nokia logos seems redundant.

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

NOOOOOO!!!!!

Get rid of the Nokia logo all together.;)
Seriously, Estel, instead of the Nokia logo, make a Maemo logo :p

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

What ?!?!
A corp. accused of redundancy!
Impossible I say...
Incredibly impossible..
XD

It does look slick I must say...
Hmm y'ar right tho...get rid of the label altogether.
Put racing stripes on it instead!
...scientifically proven to make it go ALOT faster!

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

How about the model itself?
Also, seeing as you made your prototype on a CNC Mill, I'd be interesting in seeing pictures of your hold-downs(especially for your second side/OP2; did you use a web of material and tab it out? Hold it in a vice directly?

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

The less NOKIA the more Maemo I'd say.

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

Actually, I just about to spent another week in my workshop area (for vaious reasons, my CNC machine ended, temporaly, quite far away from where I live, so I spent a intensive "bursts" of time directly working on the project, instead of more effective "few hours every evening" :/ ).

Which reminds me, that I have a footage of prototyping process from my *last* "burst of working", that I still failed to post here (I know, what a ***** of me...). Uploading now, I hope it should answer some questions ;)

As for model in gitorious - sure, for body replacement, there will be model posted, too. For backcower there *is* no model, as everything was coded in g-codes directly, by hand (with a non-direct non-autoconvert help of 2D cad program drawings done before, which will land on gitorious too, of course).

/Estel

// Edit

And no worries, while I thank for suggestions, there is no way I'm going to get rid of camera cover and kickstand. In fact, I'm pretty fond of how those two elements turned out ;) *goes back to uploading damn photos before forgets about it AGAIN*

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

I've been thinking about this and I may be able to create a model for others here, once the G-code is posted.
I have access to Mastercam at work, and I think I may be able to back-plot code into a model, given the tools used etc.
If I can make it work, I'll post it for all.

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

It's been 2 years since my first post in this thread and I have 52 emails in my inbox from when I first subscribed to this thread on that same day.

I know that putting together a new CNC machine, designing a new backcover/full body for an existing product and milling said backcover/full body out of aluminium doesn't happen overnight and I know that Estel is doing it on a voluntary basis and that he wants everything to be perfect before he sends anything out, but I can't justify "pre-ordering" this anymore.

As such, I'm retracting my promise to purchase a full body as soon as they're available (y'know, if they do actually get finished).
I still think that what you're doing is cool and nice for the community, but I'm out.

PS: You forgot to upload the photos. Again.

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

Money were donated, more than two years past, no result.... i smell fish here