Here are the new enclosures. They are made in China so the finish quality is much lower than the previous ones from Korea. Notice how nicely the rubber attachment fits with the plastic part, using four small screws (black, same as the final rubber color) and how the logo emerges through the rubber (this will be more evident when the colors aren't white and white).
Solved problems:
- Enclosure can now be closed (enough vertical space for the battery connector) - though still not optimally (cable has to be positioned to be exactly under the recess on the top in order to fit)
- Enclosure features no longer interfere with PCB components
- Enlarged belt attachment features on the sides
Remaining problems:
- Waterproofing is still not functional; the o-ring will have to be taller as we originally requested the manufacturer. Presently you can see a very thin opening between the o-ring and the top of the enclosure. Water will definitely go in, not even worth doing any tests. He insisted we first try just a larger o-ring groove, which we now have, but this alone won't solve the problem.
- Screw holes still too small on the bottom. Screws should just slide in through the bottom but they have to be screwed in. In this prototype the hole size was enlarged but perhaps they drilled the holes too small on purpose - it was previously explained to us that by doing this one can re-drill and enlarge. Need to measure very precisely (hole was only enlarged by 0.2mm)
- one of the grommets is big and it's very hard to push it in
The "surprise" mold is still not working but we took everything apart and discovered why! And we now have a solution. This is really exciting. We talked with the manufacturer and on Saturday we'll go there again and stay at the machine until a solution emerges!
