retrohax.net

… or building the ultimate colored keyboard

Intro

Some time ago, I started a vacuum-forming project. I’ve already described it in two previous blog posts:

Vacuum forming machine build … errr fail

Colored keycaps – Vacuum forming research continued

The main goal of this project is to vacuum-wrap keyboard keycaps with vinyl foil so it is protected and colored. IMO this is a way better solution than painting with semi-transparent paint which I covered too in some of my EXTREME series blog posts:

Extreme refurbishing: Episode 1 – Commodore 64

Extreme refurbishing: Episode 4 – Vampiric Amiga 500

Vinyl wrapping cannot be easily worn out even after months of typing, whereas a paint-covered keycap might lose its color after some heavy typing spree.

The fresh idea

I like combining various techs to improve the results. This time, I decided to design and 3D print a special jig for the keycaps that would go into the VacuForm. As usual, it took several attempts to get it right but I think it was well worth the time spent on it. Also, I did that quite a while ago so the printouts are made with my old 3D printer – Anycubic I3 Mega

I had some unneeded PET-G filament on the shelf, so I decided to use it … a big mistake as the filament wasn’t dry enough, resulting in a poor-quality printout. Fortunately, in this particular project, it was not the issue.

The data that I needed to gather with the first tests was:

• Height of the jig – this directly impacts covering with a vinyl wrap of the lower parts of keycaps
• Distance between all the caps on the jig
• The proper temperature set on the machine

I ran several attempts before figuring out how to model out the part properly but I finally made it. However, this has to be done for every set of keycaps as the jigs differ from computer to computer keycap sets. Anyway, I’ve made two sets, one for Amigas and the other for C64s for starters.

I’ve made a hole under each keycap stand to fit in a small neodymium magnet so it can hold in place firmly while the vacuum pump works. However, I didn’t put magnets in all the holes as that was not necessary.

Below, are two sets populated for tests. On the left is a C64 set and on the right Amiga set.

Some foils that I’ve bought for testing.

Let’s start it!

I chose the red one because I had a lot of it.

aaaaaand…. of we go with first tests ….

Not perfect if it is about C64 keycaps as these are a bit taller than Amiga ones.

However, let’s push on with the Amiga keycaps.

Some test wrapping which is obviously wrong …

Scaling it up

Next, I’ve designed and 3D printed a larger jig as the settings for Amiga keycaps were found and tuned.

This turned out to be a complete failure as almost every single keycap was not fully covered with the red wrapping.

After a few more tests, I figured I needed to redesign the jigs and 3D print them again. However, these had to be tuned again so more trial and error tests were done.

Finally, after some time, I’ve learned what factors are important to make this work. Below, is the first successful wrapping YAY 😀

Assembling a keyboard

With a proper method figured out, I could start making it all happen. Here Is how a single keycap looks after wrapping it in the vinyl foil.

I’ve 3D printed a larger jig and used it immediately.

I’ve cut every single keycap wrapping by hand which is very time-consuming but the outcome is decent IMO.

The grand finale

This is it. After so many tries, I finally made it – a fully wrapped keyboard. The process is very time-consuming but IMO it is worth the time spent on it. I will use that method for incoming projects like the 20xAmiga project which the first out of twenty was covered HERE.

I think this Vacuum forming keyboards method is the ultimate method of personalizing your retro gear as it does not damage the original part and can be peeled off if you are bored.

Who knows, maybe someday I will offer a service of wrapping keyboards with vinyl lol … just don’t expect it will be cheap as it needs a ton of work 😀

See you in the next post 😀