Assembly

Add screws to bottom cover

Let's start by fastening two #4-40 3/8 flat Phillips machine screws into the two holes on the bottom cover part [not the holes in the corners]. Fasten until you see the screw thread slightly protrude the top of the stand-off - so, not all the way.

Mount Micro USB Lipo Charger to bottom cover

Let's mount the micro USB lipo charger to the bottom cover. Place it over the stand-offs with the machine screw lined up with the mounting hole on the lipo charger PCB. Make sure the USB charging port is facing the outter edge.  Hold the component firmly in place while you fasten the machine screw, all the way.

Mount Bluefruit EZ-Key to bottom cover

Next up, we'll need to mount the Bluefruit EZ-Key to the bottom cover. Let's do the same song and dace we just did for the lipo charger to the Bluefruit EZ-Key. Note, the mounting holes on the Bluefruit EZ-Key are just a bit smaller than the micro lipo charger, so you'll need to loosen the hole if the #4-40 machine screw doesn't go in. I used a sharp and pointy #4-40 screw to tap the hole - it just barely broke the PCB because the mounting hole is small, so do it slowly and carefully.

Mount Bluefruit EZ-Key to bottom cover

Now we have both components mounted to the bottom cover.

Mount Bluetooth Pair button to bottom cover

There's a small platform for the bluetooth pair button to rest on. You may want to bend the leads apart. Add a dap of super glue to the top surface of the platform and then quickly place the button on top, with the button facing the outter edge. Allow glue to dry before proceeding.

 

Plug in 500mAh Lithium Polymer Battery

OK, now is a good time to plug in the JST cable from the battery to the JST port on the micro USB lipo charger.

Mount Perma-Proto to bottom cover

Now we need to mount the Perma-Proto PCB to the bottom cover. Carefully coil the input wires underneath the PCB and place it on top of the two tall stand-offs. Line up the mount holes with the stand-offs and hold the PCB in place. Insert two #4-40 3/8 flat Phillips machine screws into the Perma-Proto until it's fastened to the stand offs. Fasten all the way until the PCB is completely secured.

Insert 500mAh battery

We need to insert the lithium polymer in between the Perma-Proto PCB and the bottom cover. There should be enough clearance for the battery. You'll want to arrange the wires so that they aren't being kinked or scrunched up.

Be careful not to scratch or puncture the battery!

Install Ninjaflex buttons into case

Before we insert the circuit into the top enclosure, add the ninjaflex rubbery buttons to the enclosure. These need to be in place before the circuit is installed.

Insert circuit into case

Place the circuit into the enclosure at a 45-ish degree angle so that the Perma-Proto PCB goes underneath the clips on the inside fo the enclosure. Ensure the micro USB port on the lipo charger is facing the cut out on the encosure. Carefully slide it into the enclosure, but don't close it completely, yet!

Install slide switch into case

With the circuit half-way inserted, pull out the slide switch from the circuit and press it down into the cut out for the slide switch. The clips will hold the switch and prevent it from being pushed all the way inside the enclosure.

Once the slide switch is inserted in place, close up the bottom cover!

Fasten bottom cover to case

Insert four #4-40 3/8 flat Phillips machine screws to the corners of the bottom cover. Fasten all the way to tighten and completely close the enclosure.

Add cover to top case

To finish off this project, you can add a cover to the front of the enclosure to change up color scheme. In this project I used a black color to add contrast to the pink enclosure. You can apply adhesives like E600 to the parts for a perminent seal, or you can use funtac like I did.

Charge Battery and Play!

And thats about it! The circuit is finished, project assembled and ready to play! Or is it? I recommend fully charging the 500mAh battery before playing. Plug in a micro USB cable to the lipo charger. The charger has an on-board LED indicator that lights green when the battery is fully charged. Red LED indicates the battery is charging.

Changing Button Mapping

Check the EZ-Key introduction guide for button mapping details!

Pairing with Devices

A freshly baked, 'never-been-used' Bluefruit EZ-Key will automatically start searching for a device to pair with. Your bluetooth enabled device should pick up the EZ-Key within a minute. If you're having issues with pairing, or unfamiliar with pairing bluetooth devices, you should check out the pairing page on the EZ-Key introduction guide.

This guide was first published on Feb 15, 2015. It was last updated on Feb 15, 2015. This page (Assembly) was last updated on Oct 14, 2019.