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Saturday, 9 April 2022

Problem Solving: Replicating an eReader Case [Pt 1]

Kobo Mini
My eight year old Kobo Mini eReader...
When eReaders first came out, it seemed like everyone had to have one. At the time, I pooh pooh-ed the idea as trendy and lacking in authenticity.

After all, how can you replace the experience of reading an actual book?

I was also under the (mistaken) impression that they needed to be charged with the same frequency as our other electronic gadgets. Who wants to run out of juice right in the middle of an exciting chapter?

Once it was explained to me that a single charge can last a month — or longer, depending on how often it's used — I reconsidered my opinion. After all, for traveling, it certainly beats toting around actual books. (No argument that one's range of choice of reading material is greatly expanded with this small device.)

When I encountered a "you can't pass this up" price of only $40 for a Kobo Mini, I jumped on board the eReader bandwagon and haven't looked back since. I subsequently picked up a leatherette case for it on eBay for $5.30 (shipping included). That was 2014.




Eight years on and that case is definitely showing signs of wear and tear. It's also now been a decade since the Mini's original release and with Kobo officially abandoning it in 2019, no one is selling accessories for it anymore. At least, not at a price that I care to pay.

Kobo Mini Slip Case
Front and back of my current eReader case...

So, in an odd turn of events, I've decided to tackle a project that I briefly considered in 2014: to sew a case for my Kobo Mini. Didn't make sense back then when I could buy one for almost peanuts, but obsolescence has changed all that. 

Kobo Mini Slipcase
View of inside...

Since I like virtually everything about this case, it's once again a see it — like it — make it project. Easier this time because I have the original item and can make accurate — down to an eighth of an inch — measurements and peek around corners to see how things are constructed.

But it's still a problem solving exercise since this original case is made out of non-fraying materials and I'm going to be working with fabric.

Kobo Mini Slipcase
View of the bottom...

The biggest challenge is finding a way to replicate the slip-in feature. I know that many DIY solutions employ diagonal elastic in the corners to hold things in place — kind of like old time photo corners (remember those??) — but sorry, that would look too DIY for me. Lacks elegance.

Kobo Mini Slipcase
Side view...

Therefore, I've been ruminating on this project since late last year, trying to figure out how to recreate this "harness" (for lack of a better word); i.e., the stiff frame with soft sides sewn to the base that holds the device in place.

It also isn't particularly obvious how best to approximate the book-like structure of the case. As sewers, our usual "go to" method is to stitch two pieces together and then turn it right side out to make something with a front and a back, much like you would a wallet. I could envision early on, however, that that wouldn't be the right approach for this.


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As part of my routine whenever I start thinking about making something, I take out my project book and start measuring and scribbling notes, hoping that the process triggers some lightbulbs.

Except that this time, apart from my carefully considered measurements and general thought about how I wanted to change up the orientation — I wanted my case to open up like a notepad instead of a book — I didn't get very far in documenting any actual steps.

Making a new Kobo Mini slipcase
Make a template...

Towards the end of February, I decided just to start. By then, I had found a solution for the book cover part and wanted to begin, with the expectation that clouds might lift as I went along... you know, sort of like crafting on the fly.

My first task was to make a detailed template out of card stock. Not only does it function as a template for the main panels of the case, it replicates the outline of the frame that surrounds the device.

Making a new Kobo Mini slipcase
Making the exterior panels...

I used it to cut out two pieces each of Peltex and Decor Bond. My plan was to cover them with fabric and then sew them together back to back to create the interior and exterior of the cover. It seemed an ideal way to simulate the look and feel of the original case, and didn't require turning anything right side out.

Armed with remnants of my 2021 Spoonflower competition entry fabrics (Year of the Ox and Yellow and Gray), I cut pieces about a half inch larger than the template, to allow just enough to wrap around the edge of the interfacing.

Making a new Kobo Mini slipcase
Inside of the exterior (back) panel...

The original case is padded on the outside. To give the new one some similar softness, I added a layer of fusible fleece to the exterior fabric before "sealing" it in with the Decor Bond. I then sewed around the edge.

The interior of the original case is firm and likely contains cardboard; I used Peltex to reproduce that stiffness. This time, I left the fusible side of the Peltex exposed on the back, so that when the two parts are sewn back to back later, they can also be somewhat fused together.

Making a new Kobo Mini slipcase
Fabric covered Peltex piece for the interior of the case...

This setup also lets me fuse the edge of the fabric underneath.
 
Making a new Kobo Mini slipcase
Preparing to join two halves of one "panel"...

The soft "spine" of the case was established with the bit of fabric that you see above. It's meant to be sandwiched between the two layers, but was sewn onto the Peltex layer first to ensure that it would end up straight.

Making a new Kobo Mini slipcase
Finished front cover...

And here is the finished front cover of the case, after sewing the two halves together.  

By the way, I had measured beforehand to confirm that putting the spine at the top of the case would still allow the original stylus to be held in place there. It's essentially as long as the unit is wide.


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Remember how I hoped that moving forward with the project would help develop further clarity?

Making a new Kobo Mini slipcase
How do I replicate this?

After I started, the obvious solution to use more Peltex to create that supporting harness occurred to me, but I was still stumped by the problem of how to cover it with fabric and yet still have more fabric coming down along the sides (i.e., the extension pieces that are sewn to the base).

Making a new Kobo Mini slipcase
This cutting requires a sharp knife, patience and precision...

I'm gonna hit pause here and let you ruminate on how to solve this problem. Let me know your thoughts on how you'd proceed. 

My answer came to me in the middle of the night. I almost got up to test it out. ʘ‿ʘ

'Til next...

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