Bad news and Good news!
skorpn, have you considered ordering a custom PCB? you should be able to get at least 100 for $100, but good luck getting anything at all for less than $100. you can get both the plug and receptacle for less than a dollar in quantities over 100. that means $2 per adapter in materials... if you think you can sell 100
i have 10 of each of these at work, but i haven't had time to draw the board. i could draw it and give it to you if you were interested.
http://search.digikey.com/us/en/products/10103594-0001LF/609-4050-1-ND/2350357
http://search.digikey.com/us/en/products/10104109-0001LF/609-4051-ND/2350352
edit:drew this quickly to show you what i'm talking about
I have no clue who would sell a custom pcb at that price, but they would surely break in no time and look quite ugly (look below for my old red Samsung JIG from mid 2010). Sparkfun wanted $1500 or so for 500 micro usb breakout boards that I still had to solder together myself.
I was quoted 0.18 cents per piece for an adapter (mini female to micro male which would be ideal IMHO) that would let me add a resistor myself. They wanted $9 for 50 pieces (with $40 s&h via DHL) unassembled and I would just add the resistor, snap it together and be done with it. Only problem is they use Western Union or Money Gram which are highly dangerous (I could easily be scammed, no thanks). Its Paypal or nothing...
I paid less than 0.10 cents each for 3000 pieces for the current Samsung JIG I manufacturer
and that came with the micro port, and both sides of the casing and 3000 resistors. Monoprice wants 0.70 cents per cable OUCH, but Im going to try to get them to 50 cents per unit.
Well guys good news and bad news. Bad news first I guess. I just do not like modifying a cable, its a time consuming process, you have to cut wires super short which makes it extremely hard to work with, add a resistor beforehand with it cut and shaped VERY precisely in order to fit it in. So I have to make the wires long in order to be able to work with it, but then its almost impossible to enclose into the casing because of bunching the wires up. Im a perfectionist and need the product to look good or I won't do it, and making it look professional takes time using a cable. Took me like 45 minutes to make just one, while it takes me 10 minutes or less to make a Samsung JIG. I'd love to do this for the Kindle folks, really I would but to give up that much time for a couple dollars each order is to much, even for my giving personality (I have to think of myself also). First Class shipping is $1.75 for anything weighing more than 1oz-13oz (which is what I pay now). So, I just don't feel comfortable committing to this project at the price point I was shooting for. I think the best I would be willing to do using a cable as the basis for this mod is $14.95 minimum (I will pay the shipping out of that). As time moves on and I get the process down easier and faster I will more than likely drop it some. The work is just ten fold more than what Im doing now for $5.95 and there's no way around that (except modifying an adapter would get us around that I believe) If I can find an adapter that already has the wires soldered and all I have to do is toss a resistor into it the mix (which was my initial offer) and snap it back together, I would then be Ok with $6 bucks per (Depending on initial cost of course). There's just to much work involed with this mod at that price point. I have to pay for shipping Labels, padded envelopes, my packing slips, my thank you and Instructions letters (yes I have one in every device I mod or ship), my resistors, hot glue, the cables, the connectors and the S&H.
Another major problem is that I have no Kindle to test this myself. I test my JIG's three times on my phone and once on my custom bench tester before shipping out. How in the heck will I know it will work when you get it? I have a perfect seller rating 5 stars for 5 stars for every category and I don't want to lose it from someone who may be upset at me because it did not work for them, lol... I had initially thought that I could just use my current bench tester I built for my JIG's but I come to realize that back in 2010 I cut the pcb for pins 1-3 and hot glued it into my bench. Meaning I can only ohm out pins 4 and 5. This device requires I test all 5 pins for continuity and pins 1 + 4 for 1k Ohms. And I currently cant even do that without physically doing it with my meter, which trust me IS NOT EASY on the micro side, lol. I Think for starters I'm going to have to ask for $14.95 in order to feel good about it. That is what my Sammy JIG's sold for for nearly a year and it is much less work. Hope peeps understand...
Bellow are pics of my very first one. I have no clue if it works or not. I did NOT put my LOGO on it as I do not want to waste one not knowing if it works or not. lol
The cables rubber cover and some of the shielding is solidly glued down into the plastic. Then I glue over the top of it again making it pretty much filled with hardened hot glue. If you look hard enough you just might see the 1k resistor that I had to put into a ridiculously tight and custom shape (This glue I use is used in the auto field to pull dents)
And now with 400 degree dent pulling PDR Hot Glue to hold it all in. DONT touch!
And the final product feeling rock solid in my hands.
NOT for the Kindle. This was my first JIG for Samsung smartphones back in 2010. I hated the PCB look. Just nothing personable about it at all.