Replacement ZX80 Cases

[RWAP]

In a mad moment this morning, I gave some serious thought as to whether it might be viable to get some replacement ZX80 cases made based on the original (of course).

There is not a large number of ZX80s in circulation, but I know that many of the cases are yellowed, cracked or snapped on the corners (generally) as well as other marks.

We would probably need to look at either 3D modelling, or go back to the original vacuum formed case in order to keep costs to a minimum.

That said, presumably some of the newer clones could use these cases too ?

The big issue would be how large a production run would be required - probably no more than 50 cases (?) - I had 50 keyboards produced and have sold 24 to date, so it is reasonable to presume that twice as many cases will have problems compared to keyboards.

As for costs - well that all depends on the costs to reverse engineer the CAD drawings (in 3D CAD ?) as well as the production. I should imagine the cases would sell for around £40-£60 each (bearing in mind the sums of money the ZX80 itself sells for in poor condition as compared to a good condition machine).

The other thing we need to find is a supplier of the W buttons which hold the motherboard in place - I can find manufacturers, but they do not respond to email enquiries or requests for samples!

What do people think - is this worth even pursuing?

[Paul]

At least I am interrested.
I was already thinking about how to produce a case on my own.
Either I make a negative of my original case and make one from polyester or I use ABS and learn how to process this with my oven and my vacuum cleaner. Both can be seen on videos in the net.

I have not found the time to try this.
So buying one would be an alternative

[Moggy]

Why not think about colours other than white I seem to remember seeing a picture of a really cool transparent case which I think may have Been Rick Dickinsons .

Moggy


EDIT It was indeed His transparent case.

http://www.flickr.com/photos/9574086@N02/4062969847/


http://www.theproductdesigners.com/ZX80/zx80.html

(PICTURE 11)

[Paul]

Transparent would definitely be cool.
Is he able to produce more of these? He must have the tools....
I also thought about using carbon fibre instead of glass fibre if I make one myself...

[PokeMon]

I like the transparent case.
And I like Rick's house in the mountains.

I think a case could be produced using 3D printers from anybody who need such a case in just kind of material he like. Maybe in the same price range - I don't know exactly.
I don't know if there is a market for this case for selling 50 pieces.
Maybe it would be a good idea to produce a complete construction kit with all you need (board, chips, resistors and so on).
For nostalgic people or people want to get to.

[Paul]

I have tried to reach Dick via email.
I hope he will get it and answer. He must have (had?) tools to make these, right?

[sirmorris]

I'd buy one. It can't be beyond the wit of man to make a mould from an existing case - but I suppose there be the issue Though 3d scanners have come a long way since my day...

C

[Paul]

Wow, what an answer! I never expected to get response and now this! Thank you very very much Rick. And of course my thanks to Moggy, my friend, for pointing me at Rick!
Does anybody of you UK guys have any connection to those people/companies mentioned by Rick?
It would be great if we could even get another step foreward!

Also in answer to Rich Mellor’s letter (please pass on) in the link you attached here :

‘W’ buttons – these were supplied by ITW Fastex (maybe under a modified name now but should still be around somewhere).

Casing. The original tools were made for ‘Lenver products’, Horndon Industrial estate, Horndon, Essex – I remember the factory was next to the main line into London from Southend. Lenver products were vacuum formers and specialised in Lamp shades. I don’t know who made the tools. They were vac forming tools or moulds – known often as ‘patterns’. The very truly original patterns were made from Wood (Jellutong), and perhaps a few hundred or even a thousand were made from these whilst aluminium patterns were being manufactured. The wood patterns don’t last long so for higher volumes resin would be the next level up, and aluminium after that.

Lenver eventually lost the ZX80 business to a company called ‘Matcon’, who had a factory in Mayland on Sea (near Southend). The production from Matcon is likely to have been from new tooling, so overall there could be at least 3 different tooled versions of the vacuum formed ZX80, and there will undoubtedly be slight differences in form or shape and detailing between these, and especially material and printing. The materials will vary from all of these factories. Some were much whiter than others, some thinner or thicker. All had different production methods for cutting out the formings from the formed sheet, and so on.

Finally, the volumes grew so high on the ZX80 that injection moulding became viable. I think it was ‘Continental Precision Tools’ at Clopton that produced the injection mould tools and a company, I can see the factory but not remember the name, near Thetford, produced the mouldings. You can tell an injection moulded ZX80 because it will have a slight texture on the external surface, be very white, and slightly thicker, and feel more robust too.

To retool the ZX80 the ideal would be to have the original component drawings (they could still exist), produced by John Pemberton who was the industrial designer then. Another approach is to reverse engineer and have a set of component drawings produced by someone that can measure the parts accurately enough, and then find a vacuum forming company that could give you a range of tooling and component cost options depending on volumes. Nice if you could find a likeminded enthusiast in that industry.

Hope that’s of some interest

Rick

[siggi]

Why not think about colours other than white I seem to remember seeing a picture of a really cool transparent case which I think may have Been Rick Dickinsons .

Moggy


EDIT It was indeed His transparent case.

http://www.flickr.com/photos/9574086@N02/4062969847/


http://www.theproductdesigners.com/ZX80/zx80.html

(PICTURE 11)

Why not use iron casting to have a more robust case compared to plastics

Some kilometers away from here is a factory of BUDERUS doing that. They need a wooden model to make a sandbed first ...

http://www.buderus-kunstguss.de/sixcms/ ... hp/2183668


Siggi

[RWAP]

Well first off I have found ITW Fastex (they still exist) - so have emailed them about the W buttons - we shall see if they respond (a UK company I tried some months ago did not respond).

Looking in their catalogue - http://itwfastex.com/docs/Fastex-Catalog.pdf, it looks as though they are part number: 254-080845-00 unless anyone else has any better ideas (they call them canoe clips)