I will stay tuned for the results, as I believe a number of RFF members are.
i think that would work - i think the camera could do with a main on/off switch as well then so that your 'ready and waiting' CCD isn't just eating your batteries.
There seems to be a somewhat firm belief that this unit needs to be a single, unified piece of hardware. It does not.
I propose a 2-piece construction. A backdoor replacement, and a baseplate unit.
The digital backdoor obviously holds the sensor, and attaches on the preexisting hinge mechanism--folding up and down in the same way that original door does. Easy on/easy off--easy cleaning. At the bottom of the door, where the original door extends into the baseplate, and is secured, the digital back will have a long, thin digital connecter strip.
...Also, it sounds like Frankie knows what he's talking about.
Are we still talking about a camera that is switchable from Film to Digi anytime we want? Frankie, it sounds like your mods make the camera more of a permanent digi?
This is a quick mock-up of what my system would look like, all parts being on a new baseplate. Stow the original base until you go back to film. The sensor would be suspended in the middle - stiff suspension so it doesn't flop all over the place, and when loading everything with the door opened, you can make sure it sits properly in place and close the door on it, securing it down with the pressure plate on the door.
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Another option I'm thinking of....
Also a replaceable baseplate model, but a thicker base plate to house a proper battery, removeable SD or micro-SD card. A base of about 3/4 inch thickness that would attach just like the original base yet give you all the room needed for extra electronics. The two film spool areas would still be utilized for the main components as in my first idea, but now the base would let us add anything we want without adding much weight to the camera.
Details. It's all in the Details. That was just a quick mock up of a general idea.
The end tab you are referring to is quite easily solved. I have two ideas already, but it's not worth putting in here yet.
I agree that such a unit would have to fit within the door space lest it require severe and irreversible changes to the camera. A unit inserted as film would surely risk sensor damage. At the same time a door unit would require some pretty strict tolerances to position the sensor properly. I don't know about you, but my M3 door has the slightest touch of play - probably enough to induce CA on a sensor.
Hobbyists can build everything, it's all matter of cost, skill and time involved. Also I think it will cost quit a few times more then commercially available products (like M9). But if you really want to take a plunge (since at least it will teach you a lot) I would recommend you to pay a visit to local hacker space and see who's around your area with skills, if any. I'm not knowledgable enough to give you insight on exact costs, time or skills required but I know it will be a huge project, actually if your asking you most likely don't want to spent all the time required in learning everything, but I might be wrong on that one.