ZeroPhone assembly checklist
photos to be added
When finishing ZeroPhone assembly, it's good to have a checklist of things that need to be done. Currently, this list only has small things that need to be done after all the main components have already been assembled (most of steps described here also belong on the "ZeroPhone manufacturing steps that are hard to automate" list)
Adding Velcro to hold back board and battery together
Currently, there's nothing that holds the battery holder and back board together, apart from the battery cable. An easy non-permanent solution is Velcro (you need to get the kind that has glue on both sides). Just cut the Velcro pieces into approx. 30mm*10mm pieces and attach them to battery and back boards.
Soldering microUSB charging port to the back board
This is done for (somewhat) better mechanical stability of the microUSB port. Soldering has to be done with something inserted in the port - otherwise, solder will flow into the port and make inserting a cable into it impossible, or just really hard.
Isolating the battery board traces&wires
This is a Gamma board revision-specific fix that won't have to be applied on subsequent revisions
Gamma 18650 holder board has traces and exposed pads on the backside, which, as it seems, made it possible for the battery to short onto various metal pins on the back board. To prevent that, apply two layers of Kapton tape over all the traces and metal on the exposed side of the 18650 holder PCB. It's also advised to apply a blob of hot glue on the place where battery wires are soldered to the 18650 board.
Connecting DC-DC output to the back board
As of now, ZeroPhone uses a 5V DC-DC module that's initially designed with a USB socket. As a result, it's hard to connect its output to the ZeroPhone back board. To do that, you need to either use short wires or 2.54 male connector pins to bridge the distance from the DC-DC board to ZeroPhone, and apply liberal amounts of solder.