How do I make a custom PSP case?

Jbbrack03 · Post by **Jbbrack03** » Wed Nov 12, 2008 4:07 pm

Hey guys, I've never tried any of this before, but I'm sure that with a little guidance, I can make it happen. First of all, I'm very tech savy and I'm very comfortable with modifying consoles (I've done a PSP and 360 before as well as building numerous computers from scratch).

We all know how unfriendly the PSP can be to the hands, and I'd like to fix that on my PSP. I know that you can buy grips and other addons to make it more comfortable, but that seems tacky to me and I'd like a more permanent solution (and I like having a project to work on). So right now I'm contemplating just making a completely different case for the PSP and transplanting all the hardware into it. In this process I plan on adding another analog stick and replacing the shoulder buttons with real triggers (probably from a xbox controller). I'd still like to keep the whole thing as small as possible and professional looking.

So, here's my step one. I've seen several great examples of custom cases for other portable consoles, but I have no idea how to make one, or what equipment I need to do it right. I'm guessing that I'm going to need to make a mold, but that's about all that I know about the process. I would greatly appreciate some guidance in this area. You guys do great work and a friend recommended that I come here with this project to learn how to make it all work. Thanks in advance for your help!!!

themadhacker · Post by **themadhacker** » Wed Nov 12, 2008 5:18 pm

A good way to make a custom case is to vacume form one.

Neildo_64 · Post by **Neildo_64** » Wed Nov 12, 2008 5:45 pm

First, you need to know what you want it to look like. Then there are a few different ways you could actually go about making it. You could use pieces of casings from other things (controllers, consoles, whatever) and piece them all together then use bondo-type stuff (epoxy sticks work great, some better than others) to fill the gaps and stuff. With this method there is a LOT of sanding and usually a decent amount of bondo work. After that, paint and enjoy. You could of course use a case that is already a case for something and modify it with this method also. OR you could build a vacuum forming table and make a mold to use. A vacuum forming table is basically a box you hook a vacuum to with holes in the top to suck plastic over a mold. The work here is making the mold, which is no way near as tedious as making a case, but still takes some time to get everything right. Your mold can be made of anything that isn't going to collapse (cardboard = fail). Wood and plaster work well. You will also need to buy some plastic. These are just a couple methods commonly used. You could also have your cases cut like Ben does, but unless you have access to a CNC machine or know someone who does, this isn't really an option.

Jbbrack03 · Post by **Jbbrack03** » Wed Nov 12, 2008 5:56 pm

I think I'd be interested more in the vacuum method. My shape is going to be pretty unique and I don't think I could really piece it all together and have it still look professional. I really like the layout of the xbox 360 controller and I'd like to get as close to that as possible while still retaining the small size.

Could someone explain the vacuum method in a little more detail? What's involved in making the vacuum table? Is there a tutorial that explains how to make a case using the vacuum table method? Thank you guys for your answers. You've been really helpful!

Neildo_64 · Post by **Neildo_64** » Wed Nov 12, 2008 10:55 pm

Check around online. Google vacuum forming table how to or something like that. Once you get how it works, you don't really even need a design or anything. Check around here (in the Case Construction forum more specifically) for what type of plastic to get and some good sources.

Mario · Post by **Mario** » Wed Nov 12, 2008 11:07 pm

For vacuum forming, check out Bacteria's thread.