Pocket Mage Beta Kit Build Guide

Pocket Mage Beta Kit Build Guide

Note: Some steps and parts differ from the final production kit. Differences will be called out inline.

[Image: Kit contents overview]

Contents Checklist

Make sure your kit includes:

• Air-dry clay
• Bag of M2 screws and M2 nuts
• Power button
• Battery (US kits only)
• Screen PCB
• Keyboard PCB
• Keyboard keys
• Top case, bottom case, lid, battery cover
• Ribbon cable
• Button matrix sticker

If anything is missing, stop and contact support.

Resin Parts Care (Beta-only)

Resin parts are more brittle than injection-molded parts.

• Handle gently; avoid flexing to prevent cracking.
• There may be trace resin residue from bulk processing.
• Wipe tacky areas with a wet paper towel or (preferably) isopropyl alcohol.
• Cure the used towel in sunlight for a few hours before trashing to avoid environmental contamination.
• Do not wash resin down the drain.

[Image: Wiping resin parts]

Remove Supports and Burrs

• Use tweezers or flush cutters to snap off supports.
• Wear eye protection; fragments can be sharp.
• Clear supports inside the battery door and ribbon cable channel.
• Ream out any burrs in screw holes and button holes for smooth fit.

[Image: Support removal locations]

Correct Warping (Top Keyboard Frame)

If the thin keyboard top frame is warped:

1. Run under hot water until slightly pliable.
2. Gently bend inward to achieve a slight concave.
3. Hold position and set under cold water.
4. Pat dry.

Avoid over-bending to prevent cracking.

[Image: Bending frame under hot water]

Pre-seat Nuts

1. Place the keyboard PCB in the top case and set the frame on top.
2. Identify fastener types:
   • Long M2 screws (~12 mm) for outer edge holes
   • Short M2 screws (~5 mm) for inner two holes
   • M2 nuts
3. Battery door: insert one M2 nut into the slot, attach with a short screw to seat, then remove screw.
4. For each case nut pocket:
   • Position the nut (tweezers help).
   • Thread the matching screw from the opposite side until snug.
   • Do not overtighten; resin can crack.
5. Back out all screws; the nuts should remain seated. Add a tiny drop of superglue if any nut is loose.

[Image: Nut seating points]

Prepare Buttons

• Detach buttons from their support tree using a dull tool (e.g., Allen key) and gentle wiggle.
• Inspect for small protrusions; remove with fingernail, light sanding, or flush cutters if buttons feel sticky when pressed.

[Image: Button cleanup]

Fill Legends with Clay

1. Lay down a paper towel to catch dust.
2. Press a tiny bit of clay into each legend:
   • Push in, then slide off to remove excess.
3. Wipe the face clean; a drop of water helps remove residue.
4. Remove any clay on button sides; it can be scraped off wet or dry.
5. Let dry.

[Image: Clay legend filling]

Apply Button Matrix Sticker

1. Ensure the keyboard PCB and workspace are dry.
2. Peel the button matrix adhesive layer carefully.
3. Align sticky side to the PCB and lay down.
4. Trim a few millimeters off the top if needed (avoid OLED overlap).
5. Press down all corners; confirm tactile buttons feel correct.

[Image: Button matrix alignment]

Install Buttons in Top Case

1. Flip the top case and drop buttons into their slots per layout.
2. If a button catches:
   • Inspect the hole for leftover support or non-circular shape.
   • Lightly ream until the button drops freely.

[Image: Button layout reference]

Assemble Keyboard Stack

1. Place the PCB onto the button-filled top case, keeping orientation upright to avoid spilling buttons.
2. Insert the screen ribbon cable:
   • Open the black latch on the screen connector.
   • Insert with blue side up.
   • Close the latch.
3. Route the ribbon through the hole to the other side.
4. Insert the power button in the top case and hold in place.
5. Install the hinge screws (short M2) loosely at first; pinch the assembly to keep alignment.
6. Carefully flip the device and verify buttons are still seated.
7. Install one long M2 screw in the center rear to stabilize, then add remaining long M2 screws around the perimeter. Tighten almost fully.
8. Test keys for stickiness; wiggle and press repeatedly to loosen if needed.
9. Final pass: tighten all screws hand-tight (avoid over-torque on resin). Typically a final quarter turn.

[Image: Perimeter screw positions]

Install Screen PCB

1. Position the screen PCB with the golden strip on the right.
2. Connect the ribbon cable and gently bend to fit; ensure no undue tension when closed.
3. Fasten with short M2 screws and M2 nuts in a cross pattern:
   • Top-right, bottom-left, top-left, bottom-right (under tab; remove protective film if needed).
4. Ensure screw heads don’t press on the screen area.

[Image: Screen mounting points]

Programming Mode and Firmware Flash

• Battery must be unplugged for flashing.
• Set DIP switch:
  • Program: ON for flashing
  • Mute: optional; ON enables buzzer

[Image: DIP switch close-up]

Enter Programming Mode

1. Hold the power button.
2. Plug in USB-C; a rear light may turn on, device shouldn’t boot.

Web Flasher

1. On a computer, open pocketmage.org and navigate to Build → Web Flasher.
2. For first install, uncheck “Preserve settings.” For updates later, leave it checked.
3. Select the newest firmware version and click Flash.
4. Choose “USB JTAG in serial debug unit” and Connect.
5. Wait for success, then unplug the device.

[Image: Web flasher page]

microSD and Boot Test

1. Insert a microSD card into the slot until it clicks.
2. Open the device and plug in USB-C to boot.
3. Confirm home screen appears.

[Image: Home screen]

Install and Connect Battery (US kits or third-party)

Warning: Incorrect polarity can damage the device.

• PCB labels: B+ (red) and B- (black). Ensure the connector orientation matches.

1. With device unplugged, align the battery notch and plug in with red wire on the B+ side.
2. Route the cable into the slot near the DIP switch.
3. Install the battery door; avoid pinching cables.
4. Secure with the remaining short M2 screw.

[Image: Battery connector orientation]

Charging Indicator

• Yellow LED on: charging
• Yellow LED off: fully charged
• Plug icon appears in the menu while charging If the device won’t power on, charge until the yellow LED turns off.

[Image: Charging LED]

Notes for Final Production Kit

• Resin brittleness, manual support removal, and warping correction may not apply.
• Fastener counts and placements will be similar but may be refined.

Troubleshooting

• Sticky keys: clean burrs, ream holes lightly, press repeatedly to loosen.
• Loose nuts: reseat with a screw, or add a tiny drop of superglue.
• Ribbon cable issues: reopen latch, reinsert fully, avoid sharp bends.
• Flashing fails: confirm Program ON, battery unplugged, hold power while plugging in, use supported browser.

Thank You

Thanks for supporting the beta and helping improve the final product.

[Image: Thanks / acknowledgments]