BEIL0014_The iPhone Case (Tray)

Equipment:
Aluminum Sheet	Guillotine
Wood Jigs	Benchtop Vise
Flat Nylon Headed Mallet	Round Nylon Headed Mallet
Sandpaper 120-600	Drill
Metal Scribe	Tinsnips

This is my favorite project. I made an iPhone case.

Russel told us, smaller radius is harder and the deeper the tray is, harder to maker. And I look at my iPhone7P, and I think an iPhone case will definitely be the final destiny of my tray.

So, I start measuring and researching.

And then I realize, I can just trace my iPhone on the wood and make a mould 1:1 size to my phone. Its quicker and easier… I did so.

Step one:

Place your iPhone on the wood and trace it. Use band saw sand the wood into right shape. (duct tapes can be used to fix multiple wood jigs together, efficiency) And use the detail information you find on the internet and measured by yourself, draw your iPhone on the metal sheet and cut the sheet in to right size. The first time I cut the metal, I forgot to leave the space for the edge… Silly…

I forget to leave the edge on my first attempt (right one).

The size I draw is slightly larger than the actual iPhone 7P. Because I decided to use this case when my iPhone is put in a thin rubber case. I don’t want my case scratch by my iPhone! Vise versa… So this is a iPhone case for iPhone with case on.

Step two:

clamp the metal sheet between wood jig by a benchtop visa. (or use metal clamp instead)

Make sure clamp tight. the tighter it is, the flatter the case will be.

Step three:

Striking the metal sheet by round head mallet. Start from the corners, as these parts need most compression and bending. I feel like this is the most difficult project so far, but I don’t really have much to talk about the techniques, all you need is patience and carefulness. I do agree that a larger radius would make life much easier, and the small radius is hard to achieve.

Step four:

Plashing hammer and flat head mallet are used to demolish all the big indents.

Step five:

Take the wood jig out. Believe it’s really hard to do. It takes times and might ruin your metal.

Step six:

Strong compression may generates excess metal on the corners, make the edge become higher than other parts of the case. Cut away excess metal by a tinsnips.

Step seven:

Make the holes for flashlight and camera! Mark the position of the holes and drill through.

Step eight:

Polishing with sandpaper and water. Start with 120 grit to sand away large and deep hammer marks, then 320 grit, 600 grit…

Sand with 120 grid sandpaper rough sand without water first,  later I used water sanding with 320,600 grit sandpaper.

Final Product:

My case and Jerome's case.