I'm envisioning some hard plastic case which has an embedded micro-USB cable to keep the internal connector from having a lot strain put on it.

Anyone have experience with anything like this?

If there are existing cases that might be a candidate I'd like to hear about it.

I believe we also have a 3d printer available as well as a plastic store that could probably cut us different shapes.

I've toyed with the idea of making a micro USB extender cable, using mylar cable (thin ribbon cable), but there are at least two issues with that:

1. There don't appear to be any mylar capable micro USB connectors on the market. All are either large cable-end items or surface mount.
2. There is little space inside the current system to mount the female end in, since it needs a good amount of space into the device (though with a thick enough case, or larger battery lid, maybe?)

I do love the idea of it though. And if you came up with a version that worked, you'd have plenty of buyers. Much easier to replace a phone case than your internal USB port. :P

If you can create a replacement back cover that has a port or some contacts that would mate with a cradle, I'd buy one from you.

Otherwise, the Otterbox for the n900 seems like it has a little extra space and you might be able to rig something up. In fact I've thought about trying it myself.