fruktstund wrote:
1. Cut a new switch hole myself - is this a good idea?
On the Phantom PCB, there is a Space Bar switch position just right to the centre of where the 2.5u Space Bar would be. I think it would be much easier for you to mod the keycap instead of the PCB: Cut away the stem and glue in a new one.
I and another guy drilled new switch holes in our ErgoDox PCBs to gain additional thumbkeys. The big problem we found was to avoid shorting the ground plane. The methods we came up with was to either paint laquer over the exposed ground traces or solder the switch to thin wires and put insulation on these before inserting the switch. I had initially tried to grind away ground-plane metal from around the holes using a Dremel tool, but that was too difficult for me. A drill press is almost essential, also.
Modifying an aluminium plate by hand to get new switch positions is possible. Steel is too hard. You will only need top and bottom or left edges touching the switch - that is where the snaps on the switch bottoms are. If you drill the PCB, then you will need those snaps because the PCB will not hold the switch.
When I built my Phantom, I modified my plate a bit. Having a second plate was a great help when cutting and filing: I first used it as a spraypainting template to get red markings where to cut, and then I used it to compare with when filing the fine bits to get the holes exactly right. The stabiliser holes were the most difficult, and unfortunately I fouled it up, so my Space Bar is a bit loose...
fruktstund wrote:3. Bug bpiphany or someone else about making a second version of the Phantom PCB, since I definitely could afford waiting that long - would this be likely to ever happen?
This would of course be the best solution.
By the way, when you tell him, please also convince him to establish some official location to download his PCB designs from, so that someone who wants to make a new run of PCBs can get the latest version.
There are a few bugs in the ErgoDox PCB designs used by Massdrop's first run (which I bought) ... and these bugs are still present in their second, third and fourth run and in the run by MechanicalKeyboards.com ...
By the way, for me, I think that the Space Bar on the JIS layout is too far to the left, My Space Bars get their shiny spots under N and M.