LaFonera Hardware SD-Card/Reader Position

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Contents

This article demonstrates a possible way of mounting an SD/MMC card reader onto the Fonera.

Fonera with a blue SD card in the card reader
Fonera with a blue SD card in the card reader

Requirements

Parts

  • A Fonera (I used a v2100, I don't know if this will work with 2200 or future versions)
  • An SD/MMC (they usualy read both) card reader to take apart, or make your own
  • Thin wire (I think mine is 0.1mm core)
  • Some thin solder for soldering
  • Strong Glue (epoxy resin or similar) OR Self adhesive plastic for a temporary solution.

Tools

  • A Stanley knife/Utility knife with a blade sutable for cutting plastic.
  • (optional) a small or medium sized file, or some abrasive paper with a small sanding block.
  • (optional) a coping saw.
  • Permanent marker, or some other way to mark the plastic.

The SD/MMC Card Reader Slot

SD/MMC - USB Card Reader
SD/MMC - USB Card Reader

I obtained a reader from an old USB SD/MMC card reader that was no longer needed. It is a simple kind with no spring eject mechanism (as found on laptop card readers). Simply desolder the reader from the slot assembly from the PCB.

SD/MMC - USB Card Reader
SD/MMC - USB Card Reader


Cutting up the Case

Mark the Location

Find a good position for the slot and card
Find a good position for the slot and card
Location marked with a permanent pen
Location marked with a permanent pen

Try to line up the reader slot so that it's edges line up with holes in the Fonera case, then mark on where you need to cut. The slot will be inserted from the inside of the case, and held in place with the small feet used to older it to the PCB originally. It should end up flush with the top and bottom of the Fonera case.

Cut the First Section

Fonera case after cutting out the hole for the reader
Fonera case after cutting out the hole for the reader

Cut through the plastic using multiple light cuts with your knife, staying inside your marked line. You can easily take more plastic off later to get a good fit, but it it harder to put it back once cut off. ;)

Dry fitting the card reader
Dry fitting the card reader

Once you have got a hole in the case, try dry fitting the card reader to check the fit. The hole will probably be a little bit to small, so use your file/paper/knife to slowly widen the hole, testing frequently for fit until you have a reasonable friction fit (the reader should stay in the hole without any help if you turn the case upside down).

Cut the SD/MMC Card Section

First Part with Holes
Insert the card into the reader to see where you need to cut next
Insert the card into the reader to see where you need to cut next
It should look something like this once this step is completed.
It should look something like this once this step is completed.

Put your card into the reader, and mark (only onto the part of the case with holes) where to cut next. I found that the card overlapped the holes on one side, so I had to take off more plastic than is necessary to get the card to fit so that I could get a smooth(ish) edge. Follow the same procedure as before to cut out roughly, then clean up the hole.

Second Part - Curved Section
The curved area cut out marked.
The curved area cut out marked.
The finished curved section.
The finished curved section.

Put a flat object onto the bottom of the Fonera, then place the SD card onto the flat object and move the card so that it is in line with the reader slot, and touching the back of the router, as if you were lining up the card to put it into the slot. Mark onto the router where you need to cut to let the card go into the socket without it extending above the base of the router. In my photo I need to cut down the outside of the vertical lines, and above the horizontal line.

If you have a coping saw you could use that to get the job done quickly (just remember that the bottom should be flat, not at an angle) otherwise you will need to use a knife, and preferabley a file to clean things up. Take it slow, and be very careful not to put to much strain on the case, as the rear section will be weakened quite a bit by taking out the curved section (the case is still very sturdy when assembled).

Assembly

Dry fit of the reader with card inside
Dry fit of the reader with card inside
Dry fit of the reader with card inside
Dry fit of the reader with card inside

You should now have something like this. The card can be inserted and removed quite easily, and the card is easily visible, so you know which card is plugged in.

The reader wired to the Fonera
The reader wired to the Fonera

Now you can follow the instructions on the LaFonera_Hardware_SD-Card page to wire up your reader to the Fonera. I soldered the wires to the bottom of the PCB instead of the top to avoid routing the wires underneath.

Make sure there is enough wire to let you take out the PCB and work on it in future (unless the reader is not glued in). You could also solder headers to the front solder points, and use two IDC plugs to create a removable reader.

Finished reader, underside
Finished reader, underside

Created by:—Hal 19:11, 3 October 2007 (CEST)