This is one of those Saturday afternoon projects that turned out much better than even I imagined.

I was needing a docking cradle for my iPod touch, but two things bothered me about buying one.  First, I didn’t want to spend the money.  But I also didn’t want to bring another piece of plastic gadgetry into the house if I could avoid it.

It occurred to me my iPod touch 2G came in an attractive jewel case.  Perhaps there’d be some way to convert it into a docking cradle.  Sure enough, there was a way and the results were jaw dropping!

Supplies needed

Here’s what you need:

• Leatherman
• Dremel with cutting blade
• Sharpie
• Jewel case used in packing your iPod 2G
• Plastic docking adapter that came with iPod 2G
• Sync cable

Step 1.  Outline the cut pattern on top of jewel case

Center the dock adapter under the TOP of the jewel case.  Then outline the INSIDE curves of the adapter.  Don’t worry if it’s not perfect, the top of the dock adapter will cover mistakes.

Step 2:  Carefully cut out a square with Dremel cutting blade

Take your dremel and cut a square in the plastic.  This makes the rest of the cutting easier.  Take your time and make this as accurate as possible.  One false move and you’ll put an ugly scratch in your case.

Step 3: Carefully SCORE the rest of pattern with Dremel

With the Dremel blade, simply follow your sharpie pattern.  I was able to cut some of the plastic away.  But I simply scored the rounded sides so I could finish with my Leatherman.  Also notice, I did NOT cut out space for the dock adapter tabs.  Later, you’ll be able to hook those in place.

Step 4: File the clear plastic until the dock adapter fits perfectly

This might take some time.  Simply file around the edges with your Leatherman until the dock adapter fits.

Step 5: File a v-notch into both side of Sync cable

Your sync cable will eventually snap into the dock adapter.  In order to do this, you need to cut and file a v-notch into each side of the top attachment near the top.  (Double click the pictures to see).

Step 6: File down “hooks” if your cable has them

Older ipod sync cables had hooks in them to keep your iPod attached.  If yours is one of these, you’ll need to file down the hooks.  Simply hold your Leatherman / file on a table and scrape the top sides of the sync components until the hooks are gone.

Step 7: File hole in dock adapter so it can fit top of sync cable (keep it snug)

Out of the box, the hole in the dock adapter is not large enough to fit the top of your sync cable.  So get to filing.  You will need to file all edges of the hole to make it wider and longer.  Tip:  Frequently insert the sync cable to make sure you aren’t making the hole too big.  You want it to just barely fit so it can support the weight of your iPod.  Eventually, it will snap into place.

Step 8: Snap top of sync cable into dock adapter

After carefully filing, you see the top of your sync adapter barely fits into the hole.  Keep pressure on it until it snaps into place.

Step 9: File notch into bottom of jewel case for sync cable to go to computer

Almost done.  File a notch approximately 1/2 inch long one one of the long edges of the bottom of the case.  You will probably want it centered but you can go an inch to the left or right if you prefer.

Step 10: Finally, put it all together

1. Insert the dock adapter into the top of the case by hooking the tabs under the clear plastic and pressing it down flush with the top of the case.
2. Place the cable over the hole you filed in the bottom of the case
3. Close the top of case to the bottom.
4. Youre done!

Step 11: Enjoy your new dock!  P.S. It doubles as a storage case

Again, this dock looks far better in person than in the pictures.  It works great too.

Remember, you can always pack up your earphones, cable, polishing cloth and other small accessories into this dock.  You might even choose to put the iPod in it too.  But you have to take it apart more.

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