Improved Pelican G5 Wallet Card Index Mod

I work outside in the elements, and sometimes in some shady locations. Having a waterproof, and RF protected wallet is a must. One didn't exist 10 years ago, so I made one. Using a Pelican 0915 Memory card case, I removed all of the innards, cut out the cross hatch bracing, lined it with thick copper tape, and made a multi card holder, and BOOM! I had what I needed. But I ended up having to making three of them as the plastic hinges/clasp would crack and it was no longer functional.

Then Pelican introduced the G5 RF Field Wallet.

The Pelican G5 RF Field Wallet is a wonderful product. It's a solid aluminum RFID-blocking shell, gasketed O-ring seal and snap-latch that makes a watertight seal and keeps your cards safe from getting crushed, soaked or electronically skimmed. Unfortunately, the functionality isn't all that great.

So I used the knowledge I gained making my custom wallet and modified the G5 into a more functional wallet.

Supplies:

1. Pelican G5 RF Field Wallet
2. 1 package three ring binder insert dividers (Clear or translucent colors)\
3. Hobby knife/ razor blade / scissors
4. Small hollow punch, or improvised one
5. Clear Tape Transparent Tape
6. Scrapers (wood, hobby knife, improvised)

Optional Supplies:

Heat gun (or hair dryer), Acetone and gloves

The G5 comes with some rubber inserts that are glued in place. And these may work for some folks, and that's great. But if you need an faster, easier way to remove and insert your cards, start by carefully removing the O ring and set aside. We want to keep it safe from damage.

Using a heat gun or hair drier on the outside and inside of the wallet to loosen up the factory adhesive. Keep your heat source moving so you don't damage the paint , and periodically use pliers to try to remove the insert. This may take a while, just be patient, eventually you be able to remove the insert.

Once you get the inserts out, you will have the chore of removing the remnants of the adhesive. This will take a while.

I used acetone (with gloves on) and a piece of a hardwood (this reduces scratches on the surface) and a special long, thin hobby blade that you use with the bevel down to prevent digging into the paint and metal (just be very cautious to minimize scratches. I was, but still had a few). After some hard work, you will finally have two clean sides to work with.

Download and print out the G5 Wallet Card Index Mod P1.pdf. Place one of the three ring binder insert dividers over printed pdf and use the clear tape in a few places around the sides to keep them together. First, using a punch, punch out at all of the folding points as indicated in the photo.(I used a #4 leather punch, but use anything that will give a smooth circle.This will prevent tearing at the different fold points). Then using a hobby knife, cut out the two shapes as shown in the picture.

Once you have them cut out, you will fold on the red LINES. (Not the red on the tabs). Keep in mind, you will fold each section in opposite directions. The G5 Wallet Card Index Mod P2.pdf and the pictures shows how it is done. Once you have made all of the line folds, then make the tab folds. They should all fold up on one side like in the picture and on the pdf. Then fold section B2, so that Tab 2 (there is no tab one) can be folded over the B3 section. The use the clear tape to secure it in place. Then repeat for the other sections. It can get confusing, just study the pictures and the G5 Wallet Card Index Mod P2.pdf for reference. When you are done you should have what looks like a mini accordion style folder. Then repeat the process for the other cut out piece. When you have completed both pieces, take Section B1 on one piece and carefully tuck it into the B5 section of the other piece and secure it with tape. Then place it into the G5 wallet body close to the hinge side with the card slots facing the clasp side of the wallet. Then tape the top of the B1 flap to the body of the wallet near the top of the B1 flap. Then tape the B5 flap at the other end of the mini accordion file,at the top of the card opening to the other side of the wallet. Again, reference the pdf and the pictures. Then reinstall the O ring and you are done.

And now you have a very functional accordion card index for your G5 wallet. There is even some room at the top for a small hard drive or anything else that will fit.

I included a picture of my original Pelican 0915 wallet and the G5 for reference.

Hope y'all enjoyed this block of instruction.

Cheers!