Anyhow, after numerous comments in the office about how loud my keyboard was (even with Browns), and my own dissatisfaction with the somewhat rattly plasticy sound it made, I came up with some ideas to improve the sound..
First mod was applying silicone grease to the rattly Costar stabilizers - this was good, but didn't solve the overall ticky-tacky sound of the keyboard. What i needed was some real sound-deadening and mass. I needed more silicone....
I still think the idea is great: I got a tube of 100% Silicone clear caulk, opened up the case, popped out the guts (metal plate and PCB), and filled the base of the keyboard case with silicone, and applied a bunch to the back of the PCB for good measure. I also filled the gap between the PCB and the upper metal plate with a bead of silcone on all sides. I then dropped the PCB/plate into the bottom of the case, wiped up the excess squeezed out, and replaced the top.
It was amazing. The keyboard sounded fantastic and was wonderfully heavy too. The sound was a lot like a good Topre board: 'thock thock thock'. It's amazing how the properties of the whole case, not just the switches, affect the sound. The switches even felt different - more solid and satisfying.
Everything was great until the next morning when some keys stopped responding. Then more... then they keyboard started spewing random characters continuously...
I looked up 'silicone caulk and electronics' and found a warning about never using acetic acid cure caulk on electronics... as it cures, it release this acid which in high concentrations will eat away at solder and copper traces.. Crap.. That's exactly what I had used!
I prised apart the keyboard again (no small feat since it was so caulked together - it took like 30 minutes of prying), and lo and behold, all the exposed solder was grey and fuzzy looking... super corroded. I could not identify anything that was actually destroyed, but I think the keyboard is a writeoff.. Maybe i can salvage the top plate and switches but desoldering them is going to be hard because the silicone caulking is pretty much impossible to remove.
So.. yeah. That was stupid.
However, i'm still totally jazzed about this idea. I just have to use a different type of caulk next time. There are varieties that release alcohol rather than acetic acid as they cure (GE Silicone II is a common type). This type should not eat the electronics, and then I can have an amazing heavy, solid sounding board again. I'll probably also try to coat the bottom of the PCB in something to prevent it from directly contacting the caulk. Maybe some paint or polyurethane.
I'm already shopping for a new victim board
