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JCat -- what can i say? i buy all my parts online and it shows up at my door.
ONWARD! i decided the case absolutely MUST have a drop down back panel (for total access to the battery pack to remove and swap batteries) and this requires a clasp to hold the panel closed, but that can be released. Further, it needs to totally fit within the 1/16" profile of the matte board used as the structure for the case. And it can't weaken the structural integrity of the matte board.
So i went round and round on this puzzle, drawing a dozen different designs until it hit me that, since the toothpick is such an integral part of the "kit" anyway, it could be used to release the catch. Here is a prototype test rig for what i came up with:
The piece of metal i am holding (with the folded end) is attached to the back panel that will be hinged. It slides into the other piece of metal (actually, it is two pieces that cover a slot in the matte board on both sides - that wire is a staple that holds the two pieces tight against the matte board -- it needs to be on the other side and out of the way of the release hole). The end of the folded end has some spring and catches the indent (the row of punches) on the inside.
Here is the clasp closed:
So, just insert the end of the toothpick into the release hole, depress the folded end, and the clasp releases.
Here is looking into the slot, to show the indents formed by a metal punch, and how they protrude inside a slot in the matte board:
Now i need to see how this actually works with the next case prototype. But based on my little test rig (shown here) i think it will be, dare i say it, perfect!
And, hey! i can actually make this sucker. in volume. (well, maybe 100 or so.)
Could this really be the LAST FUCKING PIECE of the design?
Oh, yeah -- i decided to not have a drop down panel in the front, so it won't accidently open and spill the 5/8" diameter draw tube onto the floor.