How to open the TrackR device

My initial method for opening the TrackR was a bit messy and complicated.  In reviewing how the TrackR was manufactured, I now realize that opening the device is much simpler than I originally thought.  Here is my new method for opening the TrackR case.

To start, open the battery compartment door and remove the coin-cell battery.

Basically the case is held together by two methods: double-side tape, and a snap system.  

The double-sided tape (Scotch ATG 908 for example) holds the metal outer case to the inner plastic housing.  Using this new method, you should not have to use any double-sided tape, as you will not be removing the two haves of the plastic inner casing from the outer metal case.  The double-side tape is gossamer thin and difficult and messy to work with.

The two halves of the plastic case are primarily held together by a snap system.  So by carefully inserting a thin Xacto blade between the two plastic halves, the case can be split opened.  

There is just one minor complication (ain't there always!).  The double-sided tape on the metal case extends a bit over the plastic case edges and forms a slight bond between the top plastic part and the lower plastic part.  The extend of this bond area is about 2 millimeters from the plastic case edges.  So in order to split the case open, this tape layer must be cut.  

See the photo below which shows where to start the insertion of the Xacto blade.  Again, the blade is only cutting to a depth of 2mm, not deeper.  Cut and then slightly pry upward, working your way around the case.  In other words, the cut action will break the tape bond, and the pry action will release the snaps.  You should feel the snaps popping as the case starts opening.

When finished, the opened case should look like the photo below.  

As you open the case, the button "bean" probably will fall out of its holder: don't lose it.  I suggest taping it to the back of the case after it has been opened.

If you look closely at the photo above the remnants of the double-sided tape can be seen on the blue metal case.  This can be removed by carefully rubbing it with your finger or a pencil eraser.  Its not absolutely necessary to remove it, unless your sense of ascetics requires it  :-) 

Don't open the case more than necessary: about a 45 or 50 degree angle.  This prevents metal fatigue of the metal case hinge.

To remove the PCB, open the battery compartment door so that it is all the way open.  This will allow the whole PCB to be removed.  Once the PCB has been removed from the case, you can follow the earlier posts to begin the process of installing the new firmware.

Later, when you want to close the case for actual use, you will reverse the operations used to open the case, but without reapplying the double-sided tape on the edges.  Open the battery compartment door to allow the insertion of the PCB.  Don't forget to slide the battery terminal blade into the little slot.  The PCB should now be sitting in the case without any binding.   Close the battery compartment door to keep the PCB in place.  Flip the case over so the button hole is downward and place the button "bean" into the button hole.  Now guide the two case halves together so that the snap pins align with the snap holes.  You should feels the snaps pop as the set in their respective holes.  Open the battery case and insert the battery.  You should see the blue LED begin flashing and a beep tone. Success