Eachine EV100 FPV Goggle shell replacement by Thump2010

Last crawled date: 3 years, 1 month ago

I bought the Eachine EV100 FPV goggles as my first goggles but they really didn't fit my big head, no matter how I adjusted the PID it would still blur the outside edges.
I found the replacement shell from Lichy but honestly nothing fit so I have spent a week fixing it.
I tried printing it in white so that it would not get as hot but no matter what I used ABS, PLA, PETG it lit up like a light bulb housing when the sun hit them so I printed them in black PETG.
I did however printed the face plate with a layer change, I did most of it white with the last 3-4 layers as black, that way the part that is closest to your face is white less heat conductive but still black on the inside to stop light leak.
I made and included a new control arm as I popped mine off on accident on one of the 15 different versions of this that I swapped the parts out to and it is gone forever so I made a real simple basic replacement stick, it works fine.
Doing all of the below has made it from a purchase I was questioning to something that fits my head and works well.
You should not have to force anything but the front of the top and bottom shell but that is as designed with a lip on the bottom shell to catch the inside of the top shell to make the shell nice and flush up front. (the picture shows the gap, it was the last thing I fixed and I didn't want to take new pictures but it does line up nicely now.)
Changes (that I can remember):
Made the shell 2mm shorter to get rid of the 2mm gap above the screens and to make the antennas screw on completely.
Fixed the screw distance so all the screws fit with the board no forcing it.
Fixed all the connector holes to make them fit the board.
Extended some of the plastic on the sides of the screens to close the gaps when PID is at extremes. (trying to get rid of all light leakage)
Added a lip to the front of the bottom half to catch the top of the case (it is the only thing on this design to snap fit) the bottom being the tall part seemed to bulge out a little from the top (you can see it in one of the pictures) this makes it nice and flush on the outside when the 2 halves are put together.
Fixed the screen posts being too big around so you had to force the screens down, the screens slide in place nicely now.
Added all the grooves under the screens that are in the original goggle.
Fixed the faceplate up to match the big nose cutout of the bottom half, the original was really small, much much smaller than the cutout in the bottom half.
Made the fan holder fit the fan a bit better.
Made the fan holder so you can screw it on the top shell with some m2 screws. (you can glue it or snap fit it if you like but there was plenty of room for some m2 screw heads)
Fixed the buttons to work and line up with the button switches better.
Based the faceplate shape off of a fatshark velcro pad that came with a fatshark foam kit that I bought.
Rounded a lot of edges to not cut into you or the head strap.
Made a second faceplate with a tab in the middle for a 3 point over the head, head strap.
A bunch more stuff that I can't remember right now but will come to me in the middle of the night.