How to make a carbon fiber iPod case of your own

iPod are all beautiful to look, use and in functionality, therefore the iPod deserves a case splendid case to match its style and to protect it from scratches. Thus a arbon fiber case is the best that comes to mind. This article explains a stepwise process of making a carbon fiber iPod case with the basic woodworking tools and skills, all by yourself and at the comfort of your home.

Carbon fiber iPod case

Difficulty level: Moderate

Resources Required

Caliper, Mandrel, Tape, Scale, Screwdriver, Cutter, Screws, Belt clip, Petroleum jelly, Carbon sleeve, T-nuts, Plier, Gloves and Hammer.

Instructions

Step 1: Making the case

For shallow rounded forms, you can compress the shapes under plastic bags filled with sand, clamped between wooden boards. Since the iPod has a simple rectangular shape, we can create a nicely consolidated, smooth-surfaced shell by using an internal mold (or mandrel) with blocks clamped on its large sides.

Carbon fiber iPod case

Step 2: Prepare the mandrel

Use calipers to measure the thickness and width of the iPod or any touch screen phone to create the mandrel size. The width and thickness of the mandrel should be .02" to .04" more than the iPod’s actual dimensions.

Prepare the mandrel

Step 3: Cut the Mandrel

Cut the mandrel to size, making sure that it’s very straight along its length, so it will slide out of the hardened composite after being cut by using a fence on either a table saw or band saw.

Cut the mandrel

Step 4: Wrap the tape

You should create a tight, removable sheathing by wrapping tape around the mandrel sticky side up and then wrapping it again sticky side down.

Wrap with tape

Step 5: Cut the Blocks

Cut 2 clamping blocks out of MDF scrap, making it of same size as the mandrel, without the extra 1" of length.

Cut the blocks

Step 6: Make the belt clip

Mark and drill two 1/8" diameter holes on one of the clamping blocks to add the belt clip.

Make the belt clip

Step 7: Petroleum Jelly coating

Apply a very thin coating of petroleum jelly to the set screws to keep the resin from locking them in place while cutting.

Petroleum jelly coating

Step 8: Lay up the composite

Cut 2 equal lengths of the carbon sleeve, long enough to allow the extra material to hang over each end of the mandrel. Screw the T-nuts onto the set screws and pack a small amount of modeling clay into the top of each to prevent resin from filling in the hole.

Lay up the composite

Step 9: Allow lay up to cure

Make the second layer over the first layer. Place the clamping blocks on either side of the layer and mandrel, with the holes in the drilled clamping block matching the locations of the T-nuts. Keep it for overnight.

Allow layup to cure

Step 10: Finish the case

Remove the clamps and open the clamping blocks with a flat-blade screwdriver. Pull the plastic sheathing and trim the excess ends from the composite using Dremel. Use the sand paper to smooth the surface.

Finish the case

Step 11: Painting the case

Paint the case with several spray coats of clear lacquer to give it a professional touch.

Paining the case

Step 12: Finish the belt clip

Use metal sheet snips to cut the stainless steel strip down to the length of 3", then smooth and round the edges and corners with a file. Mount the clip to the case with the button-head socket cap screws.

Finish the belt clip

Things to watch out for

Make sure to use a dust mask; carbon fiber and epoxy produce some nasty dust. Also wear gloves and be careful because cured carbon fiber slivers are even more harmful than those produced by fiberglass.