Aluminium DIY magic

[cwah]

Do you mean a lip made of silicon rubber?

 

[JamesW]

Do you mean a lip made of silicon rubber?

I mean place a sheet of silicone over the top instead of the Velcro, and attach it to the aluminium. Cut a hole in it (with rounded corners) that is just smaller than your phone. As silicone is flexible, your phone should be able to fit through the hole and be clamped between the silicone on top and the aluminium underneath. (The silicone should also prevent the phone from sliding around due to the friction between it and the phone.)
It should then be (a bit) like putting you phone inside one of those flexible silicon cases from the top/front. - I would not anticipate you having access to any controls that were accessible on the sides of the phone if you do this, but the touch screen should be fine.
(hope pic helps with concept)

 

[cwah]

You mean craving a square hole from silicone rubber? what's the best tool to do that? I suppose I'd need rotary tool? How do I make sure all the craving area is flat?

 

[cwah]

Thinking again isn't it the same as gluing a phone case on my bike?

The reason I stopped doing that is that I have multiple bike so multiple case. And each time I change mobile I have to change it everywhere.

So velcro is the most flexible solution to date

 

[JamesW]

Thinking again isn't it the same as gluing a phone case on my bike?

The reason I stopped doing that is that I have multiple bike so multiple case. And each time I change mobile I have to change it everywhere.

So velcro is the most flexible solution to date

Nope it's not, the hole just needs to be the right size to fit all your phones through (but the vertical/horizontal dimensions of the phone can be different and still fit onto the same pad through the same hole as the silicone only needs to clamp on top and bottom or both sides).
Cut a hole with a Stanley/Craft knife (sharp kitchen knife at a push) although as it's silicone and flexible, scissors can probably be used!

 

[cwah]

Shall I get this sheet as 200x200mm and 2mm thick?
http://m.ebay.co.uk/itm/261396165679?nav=SEARCH&varId=560292205005

 

[JamesW]

Shall I get this sheet as 200x200mm and 2mm thick?
http://m.ebay.co.uk/itm/261396165679?nav=SEARCH&varId=560292205005

should work, 2mm thick might actually be much thicker than you need. you can probably get away with 1mm thick depending on how tight you bond/attach it. (just think of it as a large, flat elastic band - the thicker you go the more difficult it will be to stretch to get your phone through the hole!)
I got this:
http://www.ebay.co.uk/itm/230691097798
to try make some flexible mud flaps that hang off the mudguards and reduce spatter in this horrible weather (last December). It's a bit too flexible as it collapses under it's own weight.

revision while writing:
having just checked my purchase history and seen that I got the 2mm, I'd say
2mm is too thick for your application, 1mm is the max you want to go to. (you might be able to get away with 0.5, 0.8 is probably what I would chose if it were me.)

 

[cwah]

Ok thanks makes sense. I see it as a giant elastic band!

I'm going to get 200x200mm at 0.8mm:
http://www.ebay.co.uk/itm/WHITE-SILICONE-SOLID-RUBBER-SHEET-VARIOUS-SHEET-SIZES-THICKNESSES-/261396165679?pt=LH_DefaultDomain_3&var=&hash=item3cdc6cf42f

How do I attach the rubber to the aluminium sheet? does it work automatically, do I glue, bolt?

 

[JamesW]

I would glue to the underside with epoxy resin - araldite rapid should work nicely (making sure the aluminium has no sharp edges that will cut the silicone) and reinforce with an aluminium bar (or washers) bolted/riveted over the top of it to clamp it through both sides and prevent movement around the edges. (that would be layer of metal, silicone, aluminium sheet, silicone, metal with bolt/rivet going through all where metal = washer/aluminium bar/ another aluminium plate - with a hole in on the top)

does this help explain?

(The bolts/rivets are a backup in case the glue bond starts to fail and also to clamp whilst gluing to ensure a better bond).

personally I would get this:
http://www.ebay.co.uk/itm/WHITE-SILICONE-SOLID-RUBBER-SHEET-VARIOUS-SHEET-SIZES-THICKNESSES-/261396165679?pt=LH_DefaultDomain_3&var=560572425717&hash=item3cdc6cf42f

as for another 40p you get approx an extra 50% (a4 sheet = 210x297 for £3.25 as opposed to 200x200 for £2.85) - better value for money and more to play with (you might get 2 out of the a4 sheet instead of 1, you will certainly have more left for the next time you want to pad out handlebars with rubber!)

 

[cwah]

Yes, it does absolutely make sense.

So shopping list:
- Your ebay link with 0.8mm A4 silicon rubber sheet
- Rivet gun: http://www.amazon.co.uk/Yato-professional-heavy-riveter-YT-36012/dp/B00CSU8642/ref=cm_cr_pr_product_top
- Rivet pack: http://www.amazon.co.uk/Silverline-716968-Rivets-Pack-650-Piece/dp/B000LG0TCW/ref=pd_sim_diy_3?ie=UTF8&refRID=1SZ86GV9QX50J9XABKCH
- Epoxy glue: http://www.hobbyking.com/hobbyking/store/__8683__Slow_Cure_30_Min_Epoxy_Glue_4_5_oz.html

I realise I need a rivet gun for many projects, so maybe time to invest in a tool that would be useful for any repair projects

Is that all ok?

 

[JamesW]

all looks good to me!

 

[cwah]

thanks, ordering it all now