So, having missed the deadline for Phantom and lacking a Filco, I decided about half a year ago that making my own TKL cherry keyboard and separate numpad would be an interesting side project. I figured making the case using a 2.5D design of stacked layers would be a much cheaper way of making a case, so I decided to go down this route instead of milling out of a solid block of aluminium.
After checking Geekhack, it seemed that oneproduct had a similar, yet different idea for a case in the following thread:
http://geekhack.org/index.php?topic=35402.0 Not wanting to clutter up his thread any more, I figured it was time to make my own.
IntroductionI'm making a complete TKL keyboard and separate numpad from scratch, to my own whims and whimeys. To be more precise, I'm aiming for the following:
- Part aluminium (I'm fond of shiney things, I was probably a magpie in a past life)
- Thin and not too heavy
- Caps, Num and Scroll lock LEDs next to their relevant keys
- Double-shots from the round 4 group buy (Noir)
- 1.5u - 1u - 1.5u - 6u - 1.5u - 1u - 1u - 1.5u spacebar row, with an FN key
- Not too expensive
- Programmable micro-controller on PCB
- Built to last years and years
- Plate mounted, but stems still easily swappable
I would add backlit to that list, but I never use the backlight on my QPAD anyway (plus the keyscaps wear down pretty easily). I'm also gonna have it lay flat (ergonomically ideally a keyboard should actually slope away from you, so I hear).
PCBI've got about 3 other PCBs that I want to get fabricated (about 5x5 inches each), so I figure it's easiest if I do them all in one lot from PCBWing or whatever. I've mostly done the numpad PCB, and it shouldn't be too difficult to design the TKL PCB.
I need to figure out a microcontroller I can replace the Teensy with (the Teensy adds a lot of thickness otherwise), but chances are I will go with the ATMEGA32U4, since that's the one used in the Teensy. I'll have to make some small modifications to the Phantom firmware most likely, but that should be okay (I have a programmer, and I'm quite confident with C).
CaseFirstly, note that although the following design can be made Filco/Phantom compatible, at the moment, it isn't, at least not fully. Given some measurements I'm prepared to adapt it to fit the Filco and Phantom PCBs. Namely, there isn't enough room for the controller from either PCB (thickness of back acrylic piece mostly), I'm not sure what thread width the screws to secure the PCB/plate to the case are, and I haven't got stems (or holes for hex bolts) on my case to match the extra holes on the PCB as shown here
http://geekhack.org/index.php?topic=20184.msg436409#msg436409. The top line of holes on the plate are placed correctly though, and the Filco/Phantom PCB should fit length/width wise.
So here it is, as of the 17th December. If anyone is interested in taking a look at the CAD files, feel free to PM me for them. They are in solidworks formats unfortunately, since my student edition of solidworks will only output solidworks files (bah). If someone wants to output DXF's and send them to me I'd really appreciate that.
MillingFortunately for me, the workshop in my department has kindly offered to mill the bits for me. I only need to pay for materials that they don't have, the rest is free. Fortunately, a 500x500 mm sheet of alu and a 500x600 mm sheet of 4mm perspex has come to only about £30. I should have a prototype some time in the next few months.
CAD FilesThe CAD files for this design may be found on google drive at the following address:
https://docs.google.com/open?id=0B5VeRVbgY7oLUDd2VkV2cHBmc1UBeware, again, this is unfinished and thus not Filco or Phantom compatible
yet, getting this milled will result in unhappy faces.
