I,ve posted photos of the new version.If people want to make them I can post the instructions here. Its not hard to do.Most of the work is in getting the mould right. The heating of the perspect can be done in an oven.If you wish to purchase one for $30 contact me for details.

Construction of GPS box

Materials needed
Perspex 2/140x125x3 mm
2/3/8 bolts x 70mm
2/ timber blocks 90 x 250 x 45mm or steel 220x72x20 RHS
85x45x20 timber/steel block
Small amount of rubber or closed foam for the seal
“Silicon” which is James Hardi Joint Sealant (Works well)
2/ 1/8 x 15mm S/Steel bolts
SS Strip 115 x 25 x 1mm


To make the male part of the mould. Trace the gps shape onto a suitable piece of timber or steel (20mm thick for a Garmin 201) make it about 2mm bigger, cut out and shape. Timber should be a hard wood not pine. Steel works better but it takes longer to make. Mount this onto a flat and solid piece of timber/steel (75 X 220) don’t screw/bolt through the block, it will mark your case. Screw from the back.

The female mould. Trace your gps block plus perspex thickness (ie 3mm) and cut out of timber/steel. If you’re using timber, use something thick (around 45mm) otherwise it will break when you push the perspex and male mould through it. Sand/polish all surfaces as any scratches will appear on the box and round off sharp edges.

Drill a hole at each end of the mould (3/8) so you can use bolts to squash the two halves together

Pre heat the oven to 230 deg

Cut the perspex into a 140X125 square

Heat for 6 mins

Place the female part in a vice then perspex and male on top and squash together as quick as you can then bolt together. If the mould will not completely close put both back into the oven and try again.

Shaping the box I allow about a 4mm lip and some tags each end (see photos) to pick up the bolts.

Sand the bottom flat (I use a belt sander for this, it’s quicker)

Put your GPS into the box and mark the holes. After drilling place some Gladwrap then your GPS into the box. This stops the “Silicon” from sticking to the GPS.”Silicon a small amount into the holes, enough to contact the GPS. Place into each hole a 5mm ball bearing, then “Silicon” over the top and shape with a wet finger .LEAVE it alone for 3 days to set.

The box base is a copy of the top

A strip of SS to hold the strap.

A piece of rubber or closed foam to form the seal.

To stop fog forming in the box use some water crystals to soak it up. Just a few.

GO SAILING AND ENJOY

Andrew I,ve checked the size of the 101 on the Garmin web site. The 201 and 101 are the same size,so no problems with the case.If you haven,t bought a gps yet have a look at the Navi by all accounts a better unit and cheaper.Hope this helps,Craig