Zerocat’s Coreboot Machines  v0.10.0
How to create Zerocat’s Coreboot Machines like the ZC-X230 and others...
Sleeves

How to make a sleeve for your Zerocat Laptop?

Images

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Selfmade Sleeves with Cat Logo and Wrist Loop
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Detail: Hook-And-Loop Tape
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Detail: The inner bottom Line
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Detail: The applied Cat Logo

Tools

  • damp iron
  • box with pins
  • tailor’s scissors
  • scissors for paper/cardboard
  • tailor’s chalk, white and blue
  • table with damping cloth and towel
  • sewing machine with needle, size ‘90’
  • piece of wood, 40cm of length, 1cm thickness

Materials

  • stiff, flat cardboard
  • strong cloth, i.e. canvas made of cotton, in two colors,
    a lighter color for the inner part, a stronger color for the outer
  • adhesive cotton wool, thickness 4mm, i.e. “Vlieseline H640”
  • adhesive repair botch, made of cotton
  • hook-and-loop tape (polyester)
  • belt, made of cotton or polyester
  • cotton thread, good quality!
Warning
Be careful with material made of polyester (i.e. hook-and-loop tape, wrist belt) when ironing!

Cardboard Templates

Take the cardboard and cut out your rectangular template:

  • ZC-X230 cardboard: 34.5 × 28.5cm
    • Dimensions of an X230 with small battery: 30.5 × 20.5 cm
    • Dimensions of an X230 with extended battery: 30.5 × 22.5 cm
  • ZC-X200 cardboard: 33.5 × 29.0cm
    • Dimensions of an X200 with small battery: 29.5 × 21.0cm
    • Dimensions of an X200 with extended battery: 29.5 × 23.0cm
  • ZC-X200t cardboard: 34.0 × 32.0cm
    • Dimensions of an X200t with small battery: 29.5 × 23.0cm
    • Dimensions of an X200t with extended battery: 29.5 × 25.5cm

How-To

  1. Wash the canvas by hand, separate strong colors. Let it dry over night.
  2. Clean the table, cover it with damping cloth or towel.
  3. Iron the canvas, identify face and back side.
  4. Put the canvas with its face onto the table.
  5. Cut out four rectangular pieces of canvas, two of each color.

    Use the cardboard template, align the wood along to the edges, draw with the chalk along the wood in order to add 1cm space. Use the tailor’s scissors to perform the cutout.

  6. Take the two pieces of dark colored canvas and apply adhesive cotton wool on its back.
  7. Combine two pieces of differently colored canvas and sew the top edge of the sleeve.

    Place the differently colored pieces of canvas onto each-other, face to face, and turn the cotton wool upside. Maybe, turning downside is better? Sew along one edge while keeping a distance of 1cm. That will be one of your sleeve’s top edges, so please locate the edge correctly. On your sewing machine, use step size ‘2’. Push the backwards button at the beginning and end of the line to fix the thread.

    Repeat this step once.

  8. Now turn the flaps of each newly created piece such that you can see the top edge as how it will be visible later. Iron it carefully to form a clean, sharp edge.
  9. Take the hook-and-loop tapes and cut a pieces of 3cm length, each. Place one snippet onto the lighter canvas, align it with the joint in parallel with a distance of 8 millimeters. Take care that you match the center of the canvas, otherwise the two snippets will fail to match on each-other when it comes to close the sleeve later on.
  10. Select zig-zag style, reduce step width to less than ‘1’, sew along the snippet edges. When approaching the corners, make sure the needle hits the outer corner of the zig-zag, release the foot, turn 90 degrees, press the foot down again and continue. Drive the machine manually to achieve exact results. Double check the parallel alignment of the snippet, as it tends to move while being sewed. Don't forget to fix the threads by pushing the machine’s revert button. Cut the threads when done. Reapply straight sewing pattern, reset step width back to ‘2’.
  11. Now place the two two-colored pieces of canvas onto each other, face to face. Carefully adjust their positions to match, especially the joint lines and the hook-and-loop snippets. Color #1 should now face color #1, and color #2 should face color #2.
  12. Be aware that your are going to sew around, along the edges, keeping 1cm distance. But first fix the canvas fabrics with a bunch of pins along the sewing route, now. Place the pins rectangular to the route, so that they won’t interfere the sewing procedure later on.
  13. Turn the work and place the lighter colored part in front of you. The edge that you are facing now will form the inner bottom of your sleeve. Be aware: This edge must be sewed and closed as a last step, as we need a hole to turn the sleeve inside-out.
  14. Place the wrist loop and mind the position.

    From your belt material, cut a piece of about 30cm length. Put one end onto the other to form a loop. Press the loop flat and slip it carefully between the strong colored parts of the combined sheets of canvas, at one of the side edges. To get some practice now, select an angular position, such that the loop – hidden between the canvas – crosses the line of the top edges. A small part of the belt should be visible outside, shaped triangular due to the inclined position, its shortest edge should be not less than 5mm. The distance between belt and the joint of different colored canvases should be about not less than 1.0cm. Mind this position and remove the loop. We will re-place it carefully later on, while approaching with the sewing machine.

  15. Now sew all around.

    Locate the needle of your sewing machine onto the bottom line in front of you, facing the left corner with a distance of 4cm. Start sewing towards that corner while keeping the usual distance of 1cm along the edge of the canvas. As usual, press the backwards button shortly to fix the thread at the start.

    When approaching the corner, stop sewing by pedal. Approach some last steps by driving the machine manually until the needle hits the corner exactly.

    Now release the foot of the needle, turn the canvas carefully by 90 degrees, press the foot down again, and continue with sewing by pedal. Again maintain the 1.0cm distance along the edge of the canvas.

    You are now heading towards the joint of the differently colored parts of the canvases while being on the lighter colored part.

    Stop sewing at a distance of some centimeters towards the joint.

    Now remind the previous placement of the wrist loop and relocate it thoroughly.

    Continue with sewing, carefully cross the joint, and carefully cross the belt.

    Keep on going towards the next edge, turn around by 90 degrees again as you did before, sew the bottom line of the outer sleeve, turn again at the edge, and keep on going towards the joint again.

    Now cross the joint a second time but pay attention to the correct placement of the extra canvas underneath! If the canvas or the cotton whool flips up the wrong way, release the foot, place the cloth correctly and continue sewing.

    You are now heading towards the last corner. At the corner, turn 90 degrees again, continue but stop after 4cm and press the backwards button to fix the thread at the end of the line, cut the threads.

    The bottom line should now be incomplete, leaving an aperture big enough to let your hand pass through.

    Locate the line part that is crossing the belt under the machine’s foot again. Turn the sewing pattern from straight into zig-zag, reduce the step width to ‘1’. Sew the across the belt now, but take care to not sew beyond the existing, straight line. Please use the backwards button again to fix the thread at the start and at the end of this short line. Cut the threads. Take the tiny triangular flaps and fip the backwards over the just created zig-zag line. Apply another zig-zag, but take again care not to cross the existing, straight line. Cut the threads. Done.

  16. Turn the sleeve inside-out.

    Take the tailor’s scissors and clean your work. Cut strayed threads and plies, cut the corners carefully by 45 degrees, but not too close at the edge point of the lines.

    Slip your hand into the sleeve using the bottom line aperture and turn the sleeve inside-out. Invest some careful efforts to turn the dark colored corners, but don't pay too much attention to the light colored ones.

    Iron the bottom aperture to form a clean edge. Measure the lenght of the aperture and cut a stripe of adhesive cotton whool accordingly, its width should be around 10cm. Fold that stripe along its length in the center, keep the adhesive part outside. Slip the stripe into the aperture and iron it carefully when it is placed correctly. The folded wool should not be visible outside of the aperture – in contrary, it should be hidden like 3mm along the edge. This stripe will provide some damping of the sleeve bottom thus protecting the laptop when it is slipped in.

    Finally, close the aperture by sewing along the bottom edge, keeping a distance of only 3mm.

    Now sink the lighter part of the sleeve into the darker, outer part. Move, pull and twist the canvas until it fits into place and forms a rectangular sleeve. Put some damping cloth onto it and apply some ironing.

  17. Apply the Zerocat branding.

    Take an adhesive repair botch and cut out the cat logo by means of the tailor’s scissors. A mirrored paper template of the logo will help you to find the correct shape. Place the cat onto the sleeve in a nice way, not too close to the edges. Cover the sleeve with some damping cloth, and apply some ironing for about 20 seconds. Keep moving the iron slightly, otherwise it will leave a footprint which will be hard to erase from the canvas later on.

  18. Let the sleeve – and the cat – cool down.
    Done, your sleeve is ready!

Maintenance

As the canvas has been washed already, you should be safe to wash the sleeve by hand without experiencing discoloration. The long-term reliability of the applied logo has not yet been tested, though. It might get loose.