Remove USB A jack
The PowerBoost comes with a USB A jack pre assembled. To fit with in our design, we'll need to extend the USB jack with wires so the jack can protrude outside of the enclosure.
Remove the USB jack by lifting it out of the through holes. We will need to flip the USB jack when mounting to the enclosure, so take note that the wiring will need to be flipped when soldering.
Modifying USB jack
The enclosure has a port opening for the USB jack to pass-through but first, we'll need to modify the edges on the metal case so it can fit through.
We can use a pair of flat pliers to carefully bend all four edges straight to allow the component to fit through the USB port opening.
For the wide edges, use the entire length of the pliers to grip. This will make it easier to bend back once we push it throw the 3d printed enclosure.
Be careful not to over bend the edges. The metal is pretty thin and will break off after half a dozen times bending back and forth.
Mount USB jack
Insert the USB jack from the inside of the enclosure as shown in the picture. Use both thumbs and evenly push the component through the opening. If the jack doesn't fit, double check that the edges are all straighten.
Next, the two larger pins on the sides will need to be bend flat to shorten to height of the component.
Now we can gently bend all of the edges back to keep the component from getting pushed back into the enclosure.
The middle four pins will need to be trimmed to shorten the height of the component. Cut about 2mm off each of the four pins. Don't bend the pins back as it can short the circuit.
To keep the USB component flush against the enclosure, we'll need to insert the small printed stopper in front of the plastic clip around the metal shell.
Push the edges on the USB jack into the enclosure while pressing the clip onto the metal shell.
Test the stopper clip by inserting a USB cable into the jack and then remove it to see if all of the parts stay.
To power the circuit on and off, we'll first need to wire up our slide switch. Cut two 16mm long wires and then tin and solder them on two of the pins on the slide switch like shown in the picture.
Now we can solder those wires to the EN pin and the other wire to the GND pin on the PowerBoost1000C.
USB Jack wires
Next we can go ahead start tinning the middle four pads on the opposite side of the micro USB.
The wires for the USB jack will need to be at least 27mm long to reach the port opening.
Tin each pad and then lay each wire on top to solder in place.
Male Micro USB
The PowerBoost will connect to the Qi transmitter through a male micro USB. We used the Micro-B plug and removed it from the shell.
Cut and solder two wires 50mm long as shown in the circuit diagram. We'll connect the +5v pin on the micro USB to the 5v pad on the PowerBoost and the GND on the micro USB to the G pad on the PowerBoost.
Once all of our connections are wired up and soldered, we can move on to mounting the PowerBoost into the enclosure.
We'll use M2.5 x 5mm long screws to secure the PowerBoost to the standoffs on the enclosure.
Make sure the opening for the slide switch is cleaned from any stringing left over from printing and then press the slide switch in at an angle. Use tweezers to help it snap into the three walls that will secure the slide switch in place.
Position the micro USB wires above the wires for the USB jack as shown in the picture.
Solder USB jack wires
Solder the remaining four wires from PowerBoost to the four pins on the USB jack.
Remember that all of the pins are flipped upside down!
Mount the Coil
Now we can mount the coil base to the outline on opposite side of the enclosure.
Flip the enclosure and apply two very small pieces of mounting tac to the two corner outline as shown in the picture. Position the coil over the outline with the transmitter PCB inside of the cutout.
Press down on the coil base to adhere it to the enclosure. Make sure to use a small amount of mounting tac or the coil will be too thick for the lid to close.
Mount transmitter PCB
Pass the transmitter PCB through the cutout and rest it on the standoffs on the opposite side of the enclosure.
Use M3x6mm long screws to secure the transmitter PCB to the standoffs.
Connect micro USB to Transmitter
Next we'll plug in the micro USB into the Transmitter PCB. Align the ports and use a tweezer to help guide the usb connections.
Before we attach the battery, we'll first need to attach the lid to the side of the enclosure were the coil is mounted.
Use four M2x5mm long screws to secure the lid to the enclosure.
If you are using the NinjaFlex lid part, first add the "lid support" and then the flexible lid over. The same screws will secure both lids.
Position the 6600mAh battery inside the cutout with the wires angled as shown in the picture. Use tweezers to help maneuver excess wire under the transmitter pcb.
Plug the battery into the JST port on the PowerBoost. You can use flat pliers to help align and plug the battery in.
Verify the circuit powers on and then add the lid over this side of the enclosure.