Cell Phone Dock (CAR)

Since i was going to make another car Dock for my truck and been trolling this site for years , I Thought  this would be Great for my First Instructable .  Using Multiple Adhesive Compounds ,  Zap a Gap / Zip Kicker (Cyanoacrylate) , 2 mix Epoxy Hardner, Paint safe Tape , epoxy based Paint adhesive for Flocking Fibers .


and since cellphone kits are expensive , bulky  and uglier than my neighbors face i had always opted to make them myself .

since the inception of the Nokia 6110 in 97 and being I've had at the least eight cell phones since then and  bought my truck in 2001 , everyone of those phones I've made a Docking for them  every one of them more elaborate than the next . actually the first two phones had a charging cable ,


So after Clearing space on my bench ,Gathering all the materials needed ,  taking a drive to the Hobby Shop for some Zap a Gap  ,


start cutting the ABS  ,going to 711 for a Super Gulp come back  glue the Materials together ,eat some lunch come back  fit the phone in the mold letting the Filler set  , I used this time to go to the Market  , make & Eat Dinner .
come back and sand and shape and add more filler   sand  and sand  flock the  the Dock  go get a refill for the Super Gulp , mount to the car ,  I was done  and had fun in the Process  , one days work   about 10 hours or so  , and about $4.50 for the zip kick super glue , all the other stuff i had in my garage  

So i Hope My Steps are Informative  I've Been Fabricating Stuff Like This for 20 years or so in the Car Audio Field ,I'm Not saying where but where i worked we have been featured in a lot of magazines  mini truckin , Car Audio& Electronics , Installation news , low rider   even a few others i cant remember for the life of me , So  Be Nice In your Comments, This is My First Instructable  and maybe not my Last  :)  Thanks

HTC G2 Cell Phone , or Whatever you may have !!     Any brand of paint safe , easy release masking tape , Blue 3M is Probably the best  , this is 3M as well

Use the Tape to completely cover your Phone tape shapes pretty good to get a good fit, 
add about five strips of tape to one side of phone to allow for spacing ,so its not to tight , you will be adding flocking material,   also,the tape protects it from the elements in the shop and to gap the areas when filling the epoxy

cutting the desired pieces with a bench top band saw to cut the 1/8 ABS Plastic 

i used these heavy marble bookends for stuff like this something flat with a straight angle

ok now it fits great ,gaps on the side are good , size is good . snug fit

shaping the straight edges , sanding on the flat surface using 40grit  sandpaper  i think from a planer sander ?  nice straight angles

Part A is the Filler , Part B is the Hardener  (Sorry for the blurry pics) 

Mixing the two part epoxy filler not too much ,  just a bit more of  hardener  

as soon as you slather it in the corners , slide the phone in and  let the molding process set in   , i used this time to go to the store for dinner , make and eat dinner ( oh i forgot ,to free the taped phone you can spray the taped phone with silicone spray or can put some vaseline as well but lighly coat it with a towel 

refreshed and full from dinner , peel back the tape and carefully remove your phone from the mold

relesed from the mold you have a depth of the phones impression , you can see where you can cut the corners

i use 80 grit sand paper from a DA sander for a more delicate sanding of edges

now you fill the edges blindly and use the phones impression to add filler in the sides , i didnt show that i used the band saw to take about a 1/4" of the bottom corners, and using a ball grinding tip for the dremel to grind the filler flush with the impression the phone made

Gaps are great ! sides are nice and thin corners and edges are shaped evenly all by hand .

now you want to cut out for the Charging inlet , for this i used a dremel .

on the back i added 1/4"  =  2x 1/8"  spacer of ABS 

grinded down the ABS with the dremel again and filled the edges with the epoxy filler  . ABS is  wet sanded for a smooth finish ready for  the flocking glue .  lol

this is a Suede Flocking Kit ,  by The Install Bay @ http://www.theinstallbay.com from a line of Awesome Custom Products  Endorsed by David "Fishman" Rivera 

oooooooohhhh    SUEDE !!!!!

counter sinking a 6mm thread screw

attaching the screw to a  universal cell adapter from motorola hands free kits , even the  1 1/2 " X 2"  bases will work as well  , the spacer on the back can accomodate it  That is one half of the adapter .

trimmed out a piece of ABS  , to cover the plug hole

 knotched it for the 3.5 Aux cable with the dremel .

backing retainer plate screwed in  

bracket mounted

close up

after relocating the emergency light switch to the left of the steering wheel next to the dimmer switch ,  the dock is now mounted and free from the dash overhang ,  and a thin piece of real suede liner to cover the screw .   

Final Result Sleek Smooth Suede Finish , firmly Mounted , it sits at a 78.6 deg angle, the weight of the phone  sits firmly in the dock , and since i use a 3.5 to rca adapter for audio and hands free capability  , plugged into the AUX  of my Stereo   and the 3.5 jack also  will keep the phone down ,