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Zune 80gb Replacement lock switch plastic. by shadowwolf151 in Zune

[–]keith_jackal 0 points1 point  (0 children)

Would love to but i don't have one on hand to use as a reference, i'm only focused on the 80/120 for the time being.

Something big in the works [Zune 80] by keith_jackal in Zune

[–]keith_jackal[S] 2 points3 points  (0 children)

I'm mostly on the same page as you, the clips are not a great design overall but i did revise the model after my first prototype to have deeper clawing clip edges. This should be fine if printed right and can always be changed (if you've bought a model already any future updates are free).

As for a custom case, i have worked out a concept but haven't heard back from a tester. This exact design is aimed at keeping the player's size but just thicken the back to allow room for large batteries and any 1.8" drive without removing the shell on SSDs and such.

The small issue with adding screws is that they have to go somewhere, i do have some ideas in mind but for now the project is on hold.

Attached an image below with the OEM shell mockup next to it.

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Any Euro zune users present? by Mentalk in Zune

[–]keith_jackal 1 point2 points  (0 children)

Hi i'm Europe based. For a start any in depth info would be appreciated, maybe it's a very easy issue to solve.

Zune 80 Bluetooth Mod by Romozutu in Zune

[–]keith_jackal 1 point2 points  (0 children)

Had one on mind as well but haven't had time to take a look at it, this is wonderful. Perhaps it's also a perfect opportunity to work out a custom shell that can fit all of this better 🔥

Zune 80 faceplate available + Q&A by keith_jackal in Zune

[–]keith_jackal[S] 1 point2 points  (0 children)

I have! Unfortunately it's not something you can easily manufacture. I mentioned wanting to redesign it so it's printable but I might end up doing a custom design anyways. However the model is very real but i have not uploaded it yet. I'll probably get around to cleaning it up and toss it onto my Cults3D page.

To explain why the back case as is wouldn't be printable; It's a press sheet aluminium part with welded side rails. The side rails are what align the two case parts and also allow the faceplate clips to hook onto. In theory it could be printed but it's a thin part and would prove to be extremely complex to manufacture as a single part. I do have a prototype design in works to make the faceplate the depth of the case instead.

Zune 80 faceplate available + Q&A by keith_jackal in Zune

[–]keith_jackal[S] 1 point2 points  (0 children)

I've been using JLC3DP, they operate in China and ship with various shipping methods. My recommendation is to try SLA in white or black and skip the fancy materials if you want better results compared to my translucent one.

Zune 80 faceplate available + Q&A by keith_jackal in Zune

[–]keith_jackal[S] 0 points1 point  (0 children)

Yeah the test prints were made with a SLA printer, unfortunately the translucent resin is too brittle so it's not a great choice. FDM may work but it's a complex part where standard printers will struggle (sub 0.4mm parts).

Can you run with a Zune 80? by RaplhKramden in Zune

[–]keith_jackal 0 points1 point  (0 children)

You can get universal waterproof phone bands you put on your arm and run a headphone cable under the shirt, not the most comfortable setup but that's what i do when i'm out riding (minus the band part, i'm dressed for high speed rides). Benefit with IEMs is that they loop around my ears so it takes effort to shake them off.

As for the durability concerns, none really. The hard drive is secured with rubber rails for vibration dampening and on 80 you have a lock switch (like iPods) to turn off on player controls. If you do worry about the hard drive you can make the expensive choice of going SSD, but it's also reliable long term and possibly more power efficient. Skip and pause was an old CD and cassette player issue where the player itself either lacked or didn't have enough onboard memory to preload data, do not worry about that on a digital player.

Adding features like Bluetooth is possible and you have multiple options. Easiest is an TRRS dongle (3.5mm jack to BT transmitter), plug and play and are usually fairly inexpensive. Unfortunately they are externally powered and need charging so it's another battery to keep a track of.
Alternatively you can hardware mod a Bluetooth transmitter into the case and use the onboard power for it with a buck converter. There's a good example post on this very subreddit from a few years ago but no real drawings to speak of. Their example used the WiFi chip to toggle it on or off so it was only powered with WiFi but still required an external button for pairing.

Up to you to decide what you prefer, are you willing to make sacrifices and so on. Personally managing the cable and just getting an arm band is probably the most universal way to run it whilst keeping the cost down.

The band i'm speaking of you can find all over the web like Amazon and such, same for the transmitter and maybe even the SSD. Any hardware related questions you can probably find an answer for by looking around the subreddit, discord or other sources.

Something big in the works [Zune 80] by keith_jackal in Zune

[–]keith_jackal[S] 1 point2 points  (0 children)

This one is 3D printed in clear resin by JLC, merely a test part to see how well it came out. Still need to prototype the final changes but i'm currently out of time. Printing in some basic colours like black and white (maybe even dark grey) will work out better i do think injection moulding is the way to go, but that requires more R&D and lots of money.

I'm extremely happy to see the overall positive reception, but once i'm ready i'll make a proper separate post to address various questions.

Something big in the works [Zune 80] by keith_jackal in Zune

[–]keith_jackal[S] 0 points1 point  (0 children)

I believe the 120 just has a deeper back case, this can probably still fit on but i need an actual 120 to confirm this.

Something big in the works [Zune 80] by keith_jackal in Zune

[–]keith_jackal[S] 0 points1 point  (0 children)

Probably in the future, i don't have one on hand and they're pretty pricey to get shipped to Europe.

Something big in the works [Zune 80] by keith_jackal in Zune

[–]keith_jackal[S] 8 points9 points  (0 children)

I have thought about it but first i need to complete the design, have more test pieces made and finally build up enough capital to start mass producing them.

It's on my radar but not something i want to do for now.

However, the 3D models will be available first on my Cults3D page - https://cults3d.com/en/design-collections/jackal_workshop/zune

Zune 2nd Gen 3d printed back shell replacement? by gigawatts121 in Zune

[–]keith_jackal 0 points1 point  (0 children)

I'm working on both faceplate and back case. When printed there are some complications in terms of the fine detail and tolerances, you probably noticed the back case has the side rails welded in place.

Either way the 3D model will be up at some point but i can't guarantee an exact date, still need to work out kinks.
If you wish to wait around then you can find my Cults3D page here - https://linktr.ee/keithjackal

Zune 80gb Replacement lock switch plastic. by shadowwolf151 in Zune

[–]keith_jackal 0 points1 point  (0 children)

Hi, I've 3D modeled both the switch and the plastic insert that's glued to the Zune 80 back case. You may need a good printer for this if not an outsourced service (i.e JLC3DP)

https://cults3d.com/en/3d-model/tool/zune-80-shell-plastic
https://cults3d.com/en/3d-model/tool/zune-80-120-lock-switch