Modified Dock Extender for use with an OtterBox Defender Series Case
First off I must say that the OtterBox Defender Case has got to be the best case for an iPhone. I purchase mine with the iPhone and within two days it had paid for itself. I dropped my iPhone about three feet onto concrete steps and it bounced down two more steps. I thought I would be making another trip to the Apple Store but no, the iPhone survived and the only damage to the OtterBoxs case was a tiny nick to the plastic around the bottom speaker port. And when I found that the belt-clip was too lose to hold the iPhone, OtterBox sent me the update belt-clip at no charge.
The only problem with the OtterBox Defender Case is that the iPhone has to be removed from it if you intend to attach the data-port to any type of dock. Oh it works fine with the data cable but docks need to be at least another 1/8 inch longer and most docks are designed to cradle the iPhone when docked, which can not be done when the iPhone is in the OtterBox Defender Case.
Enter the Dock Extender by SendStation Systems. As it comes from SendStation, the Dock Extender almost does the job, getting an additional 1/16 inch into the Defender Case, but not enough to lock it in place. But with the help of a simple modelers file and about fifteen minutes of work, the Dock Extender fits perfectly.
Step 1. Remove the case from the Dock Extender (Note that this, and the remaining steps, will void your warranty on the Dock Extender). The simplest way to do this is to carefully put the Dock Extender across a pen and rock the Dock Extender side to side until the case and the circuit board begin to separate. There is a small amount of goo (like the stuff that holds new credit cards to the paper, what I call credit card bogers) which I assume helps to hold the case and the circuit board together. Keep this as you should not use your own (bogers) when reassembling later. The reason you need to remove the case is that you dont want to fowl the inners with the plastic filings.
Step 2. Remove the iPhone from the Defender Case. This is to also keep the iPhones data port clear of plastic filings.
Step 3. Take the Dock Extenders case and with a modelers file, begin to remove the hips. File off enough material so that, when inserted into the data port opening of the Defender Case, you can not see a gap between the Defenders case and the Dock Extenders case.
Step 4. Clean off any plastic filings from the two cases, if you have a can of air, this will work great. Put the iPhone back in the Defenders case (might as well clear the screens protective membrane while you are at it) and reassemble the Dock Extender. When reassembling the Dock Extender, you will notice that one side of the circuit board has two tabs and the other side has one. Make sure that you are putting the case on properly by matching-up these tabs to the notches on the inside of the case.
Step 5. With everything back together, it time to test. Insert the Dock Extender into the data port. You should hear a click as the Dock Extender locks into the data port and it should take a bit of force to remove it from the port. If not, return to Step 1 and file off a bit more.
The main reason I needed the Dock Extender was that I wanted to be able to use a Blue Mikey on my iPhone without having to remove the iPhone from the protection of the Defender Case. The combination of the three looks great and works perfectly. But remember, the Dock Extender comes equipped with a matching Universal Dock insert with a removable support and three interchangeable bumper caps. So, even with this mod, you can now attach your Defender Case into almost any dock that a naked iPhone can use.