Looking for help on creating a custom Phantom keyboard.

[kakkun]

Hi guys. First time posting here. I'm planning to create a custom Phantom keyboard, and hopefully, someone here can help me out.

What I want to do:

• Phantom TKL w/ blue switches.
• Haven't decided on the keycaps yet.
• Layered case

From what I've been looking at, the innards of the keyboard seem to be simple enough. The case is what I'm probably going to need help on.

I'm thinking of doing a layered case like so:

• steel top cover
• steel mounting plate for switches
• wood frame
• steel bottom plate

Would anyone happen to have the CAD data for the steel parts, as well as info on how thick they should be?
How much space is needed inside the keyboard?
How would the Phantom be secured inside the case?

Hopefully someone here can help me out.

[Findecanor]

Remember also, that with the Phantom, the controller is a Teensy 2.0 soldered to the underside. So, a layered case would either be very thick or have a step. You would also have to figure out how to route the cable and if you want the cable to be detachable.

I attached the original plate CAD files, because I don't remember where they were I downloaded them...
The plate should be 1.5 mm thick, +- some tolerance. The vertical dimensions should be in the Cherry MX data sheet.
You could route a step in the case to make a ledge for the plate to sit on or let the plate be a full layer in the layered design - either way, you would have to make the original plate design wider. The ordinary plate design is only a mm or two wider on each side than the PCB and I think that would be too narrow for wood.
You could also put cylindrical spacers in the holes of the PCB holding the plate up.

[kakkun]

Thanks for the reply Findecanor.

You're right I can figure out the dimensions from the Cherry MX data sheet. I think the mounting plate will be part of the case layer itself. I also took a look at a photo of the Teensly. It looks like a mini USB port is the tallest thing on it.

I took a look at the CAD file. Any idea why the cutouts for the keys have notches in them instead of the squares shown in the data sheet?

[kakkun]

Got a quote from three places for the mounting plate.
One said $60, one said $110 and one said it couldn't be done cause there would be too much warping from the heat?
What should I believe? I do understand that there will be some warping, but will it be that bad? Why are the quoted prices so different?

[Findecanor]

Any idea why the cutouts for the keys have notches in them instead of the squares shown in the data sheet?

Those are there so that you will be able to open switches for modding without desoldering them from the PCB.
I forgot to mention that there is a bug in the the cutouts for the 2× stabilisers - a small notch on each side that are in the way for opening the switches. Those would have to be adjusted for, if you care about it that is.

Why are the quoted prices so different?

I don't know, but I know that most of the cost when commissioning a one-off or a small series to be machined is usually for the manual labour involved in programming the machine.
Also, did you ask for the same metal alloy? Some types of steel are harder to cut than others.