Watchband for Infokey

From SegwaySocial

by Jeff Backes

Contents 1 Why? 2 Tools Required 3 Parts Required 4 Building the Jig 5 Cutting the InfoKey 6 Melting the Spring-bar Holes 7 Installing the Watch Band

Why?

Here are the reasons I wanted to wear my InfoKey.

• My eyes just aren't as good as they used to be. I can't read my InfoKey when it's docked on the leansteer frame.
• I want my InfoKey with me when I leave my segway outside a store
• The InfoKey really makes a pretty good watch

Note: You stand a VERY good chance of ruining your InfoKey with this project. We are talking about tossing $300 out the window if you make a mistake. I take no responsibility for your InfoKey!

Tools Required

• Band Saw
• Drill Press
• 5/8" paddle bit
• Chop Saw (or Table Saw)
• Propane or MAP torch
• Needle nosed pliers

Parts Required

• 1 - Segway InfoKey
• 1 - 3/4" wide wrist watch band of your choosing. I picked up a black rubber band at the local shopping mall for $15.00
• 1 sqft of MDF
• 1 ft 5/8" wooden dowel
• 1 - Large pin used to hold items on cubicle walls

Building the Jig

In order to cut into the watch accurately, you need to build a jig that will hold the InfoKey in place while you nibble away some of the plastic

1. Using your chopsaw cut one piece of MDF 3 1/2" x 8 /2"
2. Using your chopsaw cut 4 pieces of 5/8" dowl
3. Using your drill press drill four holes in the MDF as shown in the diagram
4. Place the four pieces of dowl into the four holes in the MDF and make sure they have a little wiggle room.
5. Using your band saw cut out the area in front of the InfoKey as show in the diagram
6. Place the InfoKey into the jig as shown. Make sure it fits snugly and that the InfoKey bottom touches the MDF. If this is not a snug fit you could damage the InfoKey in the next steps. If the InfoKey does not fit well trim or shim until it does.
7. Cut two 4"x4" pieces of MDF to use as stop blocks

Cutting the InfoKey

NOTE: Remember that part about tossing $300 out the window if you make a mistake? Here's where it all happens. Don't try this if you don't have a backup key!

Before you do the actual cutting you need to setup your band saw. Install a fine tooth wood cutting blade NOT a metal blade. You will be hitting two very small screws, but this should not hurt a good quality blade.

You need to install two stop blocks, one on each side of the jig, these limit motion left-right (width of cut) and front-back (depth of cut). This is one of those step you really, really, really, need to take your time. I had a spare non-working InfoKey to start with, you probably won't.

My watchband is 3/4" wide so I needed to limit the side-to-side movement of the jig the same amount. Center the jig on the table and center it. move each stop-block 3/8" away from the jig

I want to cut out 1/4" from the center of the InfoKey, so I moved the stop-blocks 1/4" away from the miter gauge when the blade of the table saw was just touching the center part of the InfoKey.

The Actual Cutting Begins

NOTE: Your InfoKey is about to lose its water tight seal, please make sure you understand the risks before continuing.

Moving slowing starting with the jig flush against the left push block, make your first cut, move the key over 1/16" and cut again, repeat over and over until you have removed all of the desired material from the top of the InfoKey. At the middle of the InfoKey you will be cutting through a screw, this is true for both top and bottom of the key. If you have a good blade in your saw this should not be a problem, just remember it's there and feed the jig accordingly.

Rotate the watch 180° and repeat the process.

When you are finished you should have two 3/4" notches in your InfoKey.

Melting the Spring-bar Holes

A watchband is held in place with spring loaded pins called spring-bars. These go though the watch band and seat into holes in the watch. If you don't mind taking your InfoKey totally apart, you could use a drill to make the holes, but I just don't want to take that much time.

Take a cube pin as shown and bend 3/16" from the tip at 90°.

Look at the notch you have cut, you want to place four holes in the InfoKey. Center them on each side of the notch front to back and side to side. Heat the pin using the torch until it glows red. Before it has a chance to cool too much, poke the pin into the side of the notch's edge center top-to-bottom back-to-front. Keep the pin moving so that it doesn't get stuck in the InfoKey.

Using a sharp knife, trim the plastic that was ejected when the pin was inserted.

Installing the Watch Band

This part can take longer than all of the rest put together depending on your manual dexterity. Take one of the pins that came with your watch band and install it in the InfoKey without the band itself. This step gives you and idea of how far the pin will be from the edges when the band is installed. Using a sharp knife, remove the pin and reinstall with the band one piece has a buckle, that goes on the top of the watch the other end has the holes the the buckle uses, it goes on the bottom of the watch.

http://www.youtube.com/watch?v=TtPde-M5Xz0