actually i should post this somewhere as i'm not sure i have it all out there anywhere but my head. here's the construction process for an ssk revival keyboard:
INTERNALS ASSEMBLY
1) drill out the plastic rivets from a new barrel plate, as in any other bolt mod (well, with a new barrel plate). currently, this is being done with rknize's manual mill, because he was naive enough to offer a while ago, muahahahaha.
2) modify a new IBM-matrix model M 104 membrane by slicing off the tenkey. bridge the cut traces as appropriate using a combination of small gauge magnet wire, and conductive copper tape. some of the details of this are TBA. i've used a variety of bridging materials and haven't been entirely happy with any of them. these seem to have the most promise out of those that remain. the beta boards actually just folded the excess membrane over, which works fine electrically and mechanically (for the most part... jury's still out on that actually, it may have contributed to some of the problems that were partly due to warpage of the backplates) but is inelegant, and may not work so well with the new case design.
3) sandwich 2 pcs new stamped steel backplate, ABS barrel plate, and M membrane, secure with 2mm-longer-than-normal-bolt mod screws (which iirc are M3, but i have hundreds at home and will correct this when i get there). secure with lock washers, 4mm nuts. torque to 2inlbs. (again, i may have to correct this when i get home).
4) attach to new SSK controller board. wire ground to somewhere sufficiently large and conductive.
CASE ASSEMBLY -- MOSTLY TBA
1) print 2 ABS assembly-side-pieces. the reason why we need these is because we need to want to form-fit the curved assembly at the edges. for support reasons. now that our printing costs are significantly lower, the sketches you saw will probably be widened, actually -- the original design attempted to minimize volume due to printing cost.
2) print a pcb retainer. because we can.
3) fasten both to cut and press bent sheet metal frame that will serve as keyboard outer. we're probably looking at thin stainless, because it's cool, and because the assembly mostly supports itself if you give it a nice but minimal platform.