I modified my Compaq iPAQ CompactFlash (CF) Expansion Pack to reduce its size. The modification is based on the original Silver Slider design by George Mosquera, with slight adaptations.
Version 1
Tools
- Torx screwdriver (T6 size)
- Dremel rotary tool (=a miniature drill) with various sanding and cutting accessories
- DeWalt palm grip sander
- fine grain (200 & 400 grit) sandpaper
Materials
- small can of Bondo brand automotive dent filler
- spray can of primer (I used Dupli-Color automotive spray primer)
- spray can of paint (I used Dupli-Color automotive spray paint)
Most of these supplies can be found in your nearby automotive parts store such as Kragen.
Version 2 – New & Improved!
My initial implementation of this modification turned out not to be very sturdy. The lip of the CompactFlash slot (a thin metal plate) started tearing apart due to abrasion & repeated collisions with clothing, furniture, etc. The PCB assembly separated slightly from the plastic jacket, causing hairline fractures to appear along the sides. Pieces of Bondo and paint started chipping as well. All in all, it was becoming a mess. Fortunately I had finally been able to purchase the Compaq iPAQ PC Card Expansion Pack, so I was able to retire the CF Expansion Pack for some retrofit work.
First, I separated the PCB assembly from the plastic jacket and cleaned up some of the Bondo. Then I re-assembled the Expansion Pack again, but this time I applied liberal doses of fast setting epoxy glue in between the parts. Much to my horror the CF slot started filling up with excess epoxy squishing out from between the parts! I thought the Expansion Pack was a total loss but decided to withhold judgent until the epoxy set. Fortunately I was able to chip away the epoxy from the connector pins using a small jeweler’s flathead screwdriver.
After confirming that the Expansion Pack still worked, I continued with the retrofit work. I decided to cut off the previously down-swept wings of the sides to make it visually and ergonomically pleasing. I also cut out the Compaq logo from the original CF Expansion Pack back panel along the semi-circular groove. Using the top two Torx screws and more epoxy glue, I secured the logo to the back of the CF Expansion Pack. This served two purposes: first, it reinforces the top part making it much more sturdy, and second, it hides the sharp corners of the metal slot frame. Finally I applied plenty of Bondo to fill in all nooks and crannies in both the bottom part as well as around the Compaq logo plate up at the top.
Here comes the fun part. Using the Dremel drill and the DeWalt sander I smoothed out the excess Bondo and epoxy glue, leaving it pretty close to final shape. I sanded the final touches by hand to avoid gouging too much: the power tools are, er, powerful, and the plastic tends to melt pretty easy.
Finally I applied two coats of primer and two coats of paint as in version 1. However, this time I also applied two coats of spray clear top coat to protect the paint from abrasion. So far it looks pretty good.
The materials list is the same as above, except for the following additions:
- fast setting epoxy glue
- spray can of clear top coat (I used Dupli-Color automotive spray clear top coat)