DIY Happy Hacking Keyboard alike

DIY Happy Hacking Keyboard alike
(from Sun Type 6 USB keyboard)

Once upon the time my laptop's keyboard broke. I needed to work with the
computer, so I have decide to use external keyboard. I do like keyboards from
Sun (except for Type 7 ones, and for those with swapped Ctrl and Caps). It
happened that I had one spare at home, but alas, it was quite big for my small
home workplace. I got inspired by Happy Hacking Keyboard and decided
to create something similar. I choose to have version with cursor keys, even if hjkl
should be enough for working with THE editor. You can create your own HHK too,
see process below.

You need working Sun Type 6 USB keyboard.
Top view.

Fresh new Sun Type 6 USB keyboard.
Bottom view.
Notice 2 grey latches up and 3 down.
You need to pry them to be able to take
keyboard appart (see next picture).

Upper deck taken away.
Unscrew three screws with Phillips screwdriver.

Pick up keyboard, take membrane with electronics
and rubber keys out.

Put keyboard together, leave membrane with
electronics, screws and rubber keys out.

Now take saw and cut left side off. Be carefull,
do not break saw blade (as I did) there is sheet
metal in the keyboard. Cut the keyboard as close
to Help key as possible.

Cut right side off. I broke 4 saw blades doing this. :-(
Few weeks after this I bought Dremel rotary tool.
Cut as close to Num Lock key as possible.

Take keyboard apart. Take membrane and fold it.
Be sure to apply tape to not used contact to prevent
accidental pressing. Put membrane into keyboard.

Put rubber keys on bottom part of keyboard and
membrane. Carefully cut off parts you do not need
from left and right side.

Put keyboard together (screw the screws
inside keyboard, make latches click). And ...

... and you will find, that some keys on the left and some keys on the right
side are not working. As I found. After small investigation I have discovered,
that with keys I dont need I cut off joints/latches which held upper and bottom
parts of the keyboard together and helped keys to be pressed and right contacts
to be connected. After this, I have decided to drill holes through the keyboard
and put screws with nuts there to hold keyboard firm together. When doing this
you need to carefully choose where to drill, to be sure not to drill through
membrane in wrong place.

This is me, frustrated, that my DIY HHK is
not done yet.

I neded to remove keys to be able to access
6 screws. I used screws with low flat head,
to be able to use washers and still allow
keys to be pressed.

Screws detail.

Bottom of the keyboard. Washers and low nuts
are used. After tightening the screws, I have
cut off overhang parts. Be sure to notice
(unfocused) black piece of rubber which I took
from part of the keyboard I cut off and
stick it to new keyboard.

Bottom detail. I need to cut from from the
plastic bottom part to be able to tighten the nut.
Also check left side for another piece of black
rubber.

Me cutting off overhang screws parts.
Check right side of the keyboard, work is
done there already.

Because together with unneeded parts of the
keyboard I cut off legs and I like my keyboard
height adjustable, I used screws to attach
them to new keyboard.

Bottom of the keyboard with legs attached.

Last cosmetic details. I need to come with
something to blind sides of the keyboard but
to keep keyboard dismountable.

Feel free to contact me at my e-mail.

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