As promised, AltoidsPhone v2.0

OK, so here's the guts of the beast before I started cutting anything.



Top view



Bottom view



This time I had the good sense to tape off the fragile stuff while I worked so I wouldn't be scratching screens and suchlike.



So, in the best tradition of "Measure twice, cut once", I measured the depth of the inside of the tin with a caliper, so that I could grind the top of the PCB more accurately than before. The plan with this iteration was to keep the original speaker/mic combination to clean up the wiring a bit.



And grind I did.



Until it fit



So here I'm trying to preserve as much of the original chassis as possible. After cutting the top and bottom of both halves of the chassis off in order to hold both keypad and battery in place, I managed to salvage even the eccentric motor for the "vibrate" feature. That's the pink thing off to the right.



OK, so the whole shebang fits into the old tin. That's nice.



Here's the new tin I cut for this phone, outside (note holes punched for earphone/microphone):



and inside:



So yeah, it really does fit. Inside:



and outside (actually out of place, time-wise, as the holes in the face are not punched in this pic. I must have been just fitting it to see how it settled into place, pre-epoxy):



Assembled and ready to be epoxied into place -- note that I did not use any stand-offs this time around:



The card stock is a spacer to make sure that I had sufficient space to use it as an insulation after the epoxy cured.



Here's where the soldering is gonna happen:




And here's the solder joint. Much nicer than last time, don't you think?




Antenna mounted. Notice that it's inverted from the last iteration. That allowed it to sort of hide under the lip of the lid. It's practically invisible with the paint and all, now that it's done:



So here it is, finished. Notice the signal bars on the screen, as well as the earphone/microphone holes, which I ended up having to enlarge a bit:



So what's it look like inside? Why, just like an Altoids tin:



But what's that hiding inside?



All in all, a totally fun and totally pointless project. I freaking rock.