I got the Apple Wireless Bluetooth Keyboard A1314 keyboard for free then noticed it was missing the end cap for the battery compartment.
readers digest version - made a plastic 5/8" bolt from some instaMold I had and a 5/8" nut. used aluminum foil to complete the circuit. still a work in progress but functional.
while I will probably 'splurge' for a new end cap online at some point, this turned into an opportunity to try out the instaMold I have had for a long time but never opened.
details
-Before proceeding, I wanted to know if the keyboard worked. Put in 2 fresh AA batteries with a small piece of tin foil to connect the circuit between the end of the battery and the inside wall of the battery compartment. Used my pinky finger to compress in the batteries and complete the circuit. It worked.
- first step was to determine the thread size. I did some initial queries on line that seemed to narrow it down to 5/8". Went to local hardware store, with keyboard, to verify 5/8" bolt would fit. Gently as the threads are aluminum. Verified 5/8".
- I was hoping they had a nylon 5/8" bolt that I could dremel but all they had was Zinc 1 1/2 in length and that was way too heavy and long, even for a prototype.
- Decided to try to make one using instaMold since operating environmentwill be benign
- Used a 5/8" nut as a mold and coated inside with some vegetable oil.
- Used about a tablespoon of the plastic beads. That was 2x what I needed.
- pressed the softened plastic into the nut then used a coin (quarter) to create a slot on one side.
- only minor issue was I was not paying close attention and some of the plastic formed to the outside of the nut and had to be trimmed in order to back out the plastic bolt.
- the width of the nut is 2x what is needed so will need to be trimmed if trying to make it flush
- after inserting the 2 AA batteries (positive end towards the middle) I cut a couple of small pieces of tin foil and placed on the negative end of the last battery making sure some of the aluminum touched the inside of the cylinder. This is needed to complete the circuit. trying to put it on the thread of the plastic bolt does not work due to the tolerances.
- result is ugly but functional until I get around to creating an amazon order over $25 so I get free shipping
Things to pay attention to or try if there is a next time
- length of bolt. I pushed the softened plastic all the way into the nut with the nut laying flat on a countertop. this made sure the plastic conformed to the threads and also had a flat end. It also resulted in a bolt that was 2x too long. Could try and cut the bolt via dremel or and insert a metal bolt in one end to shorten the effective width of the nut and therefore the length of the bolt. while I don't think having a flat end is critical, i would be concerned that only trying to push the plastic half way would not get plastic to conform properly to the nut threads.
- as you can rework the plastic easily by just reheating, I would create the thread part first with a simple handle to unscrew the bolt from the nut. then reheat just the top part to create the slot.
