Grey, I agree that is looks like the cord is a spring-loaded re-tractable cord. I may take a crack at designing a mechanism to retract the cord. Creating a spring wound reel isn't the hard part, creating a mechanism to lock the cord at a set position is the hard part. However, I want to keep the high voltage electronics for the Geiger counter isolated, and may need the space for that.
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Currently I am working out all the locations for the internal circuit boards, the image above is far from final, but gives you an idea of how much is packed inside.. The Beaglebone Black just barely fits inside.
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Each knob and switch will have its own small PCB. This way the system can be tested prior to assembly. The above image shows the power button board. It uses an amber illuminated tactile switch with a clear cap. A JST connector and short est of wires will connect it to the motherboard. The trim on the switch is a modified finishing washer.
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I am going to use a simple CdS Photocell as an ambient light sensor. It will be soldered directly to a connector (or cable), and hot-glued into the clip-in cover.
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I determined that the amber button on the very top of the Pip-boy is labeled "Light". This makes me think that perhaps the white pod on the back of the Pip-boy is a light. On the Pip-boy 3000 the "flashlight" was nothing more than the screen going full bright. At least one person has told me the pod isn't a light, but I don't know what their source was.
In either case, there is a small amount of room for a set of forward facing LEDs (Flashlight mode), and a set of LED strips (Lamp mode). It is a bit of a risk having LEDs close to the 500V signal needed for the geiger counter. The risk being that the LEDs will burn out if a stray arc crosses into their circuit. So it may end up being that you either select a kit with a light, or a kit with a geiger counter. If I skip the geiger counter, then a IR temperature sensor could be installed in its place.
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Here is a rendering of what the pod might look like when illuminated. I like the lamp effect, but I think I may ditch the forward facing LEDs.
Any opinions on the light? Anyone else have a source stating that the white pod isn't a lamp?