Things You'll Need:
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Step 1
Measure and write down the dimensions for the length, width and depth/height of your iPod Nano. You will also need to measure the length and width of the screen, the diameter of the click wheel, length and width of the hold button, the length and width of the dock connector area, and the space from the sides for all of those openings.
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Step 2
Draw a template for the duct tape case on a piece of paper, using the measurements you took in Step 2.
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Step 3
Use a pencil and ruler to draw dotted lines the length and width of your Nano.
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Step 4
Place another dotted line all the way around the first box you drew, space equal to the depth of your iPod. Extend the lines of the first box out to meet the lines of the second box, so that there are boxes in the corners.
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Step 5
Apply solid lines to draw in the area for the screen and a compass to draw in the click wheel, inside the first box you drew. Make sure they are the proper distance from the sides.
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Step 6
Draw in the spaces for the hold button, dock connector and headphone jack, in the space between the first and second boxes.
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Step 7
Add the flaps, at the top and bottom. They should be about 2 inches tall, and the edges should line up with the edges of the first (smaller) box that you drew.
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Step 8
Use dotted lines to add a third box. This box's left edge will share the dotted line of the second box's right edge. It should be the same length and width as the first box you drew, and it should line up with the first box.
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Step 9
Insert one last box to the right, the height and depth of your Nano.
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Step 10
Trace the outside edge of the entire outer edge, so that the outer perimeter of the whole template is a solid line.
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Step 1
Turn your paper over and tape the back of it entirely with overlapping pieces of duct tape.
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Step 2
Cut along the solid line of the case's shape with scissors. Cut out the holes for the screen, click wheel, hold button, and dock connector with a penknife. Use a small hole punch to cut out the space for the headphone jack.
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Step 3
Score all of the dotted lines with the penknife, so that they bend easily on the dotted lines.
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Step 4
Tape over the template's front with more overlapping pieces of duct tape. Trim off the excess tape around the edges of the template. Place it sticky side up and re-cut out the areas for the screen, click wheel, hold button, dock connector and headphone jack.
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Step 5
Cut two pieces of clear packing tape. Put them together, sticky sides together. Repeat, so that you end up with two pieces of clear plastic. Trim one so it will be just a little larger than the screen opening, and one so it will be just a little larger than the click wheel opening (you'll want a little overlap).
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Step 6
Place your case on the table so that the openings for the screen and click wheel are on your right and the screen hole is on the top. Use duct tape to securely fix the pieces of plastic coverings you made in the previous step to the inside of the case.
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Step 7
Fold the duct taped template on the scored lines, so that it actually looks like a case. Use the duct tape as necessary to secure it together. Leave the top flap untaped so that you can get your iPod in and out of the case.
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Step 8
Put a small strip of self-adhesive hook-and-eye tape on the top flap to secure it. It's best to put the stiff side on the case and the soft side on the flap.
