Use a hobby knife to clean any filament around the slots for each component.
Make sure to check the tolerence for each part before trimming away too much material.
Fit the speaker cover from the back of the top case. It should have a tight tolerence so it can stay place.
The speaker press fits inside the speaker slot as shown. Make sure to trim away any filament if it's too tight.
A SIM card is required for making phone calls. The Ting SIM card can snap apart into standard, mini, micro and nano SIM sizes. Insert the SIM into the Fona with the SIM pins facing down.
Lay the two cases side by side as shown and measrue each wire from the Fona to the mounting slots of each component. Leave a little extra slack to adjust wire sizes if needed.
Remove the rubber ring around the mic to allow it to fit inside the mic slot.
Pass the wires through the mic slot and carefully wedge the mic into place until it's flush with the sqaure mic grill indent.
To mount the buttons to the panel, we'll need to bend the pins stright out so they sit flush on the mounting plate.
LEDs can be mounted on top of the button actuator with a small amount of glue or mounting tac. Be careful not to get any glue inside the button.
Align the buttons with the square grooves on the mounting plate.
Use tac to mount the LEDs to the plate.
Slide the three color buttons through the top slot with the red button in the middle. The two black buttons mount in the bottom row.
Align the standoffs on the mounting plate to the standoffs on the case. Use #2-56 screws to attach the button plate to the case.
Make sure the LEDs are aligned and can equally diffuse each printed button. You can nudge them into place with a twezzer.
The motor requires a resistor, diode and transistor to work, follow the circuit as shown.
Measure wires, solder the parts together and then mount the motor in the circular slot on the case.
You will want the slide switch on the battery, not the ENABLE pin. Shorten and solder a JST extension cable to the slide switch as shown.
Position the battery so the wires are close to the slide switch. Affix the battery to the case using double stick tape or mounting tac.
Mount the slide switch into slot and attach the uFL antenna to the Fona. Use tac to mount the vibration circuit next to the motor. You can apply tac to the transistor to keep it in place.
Bundle the button and LED wires with shrink tube or tape.
The two parts of the case snap fit together without any screws. Join one edge of the case and then apply a small amount of force to snap the opposite side together.
The cover hinge utilizes a piece of 1.75mm filament. Measure and cut a piece the length of the case.
Press the cover onto the case and then fit the filament through the holes in the case and the cover.
Use flush cutters to trim off the ends of the filament.
You can push the filament out with another piece of filament if you ever need to remove the cover.
Use a piece of tape to attach the microphone grill to the button cover. Cut a small piece and stick it to backside of the button cover.
Align the two buttons through the cover and slide the button cover in at an angle. Apply a small amount of force to snap fit the cover to the case.
Your real working communicator is now complete! Flip on the slide switch and make a test call.
Live long and prosper :)