ZN-40? Sounds Doable!

[Demonmisfit]

So I've been spending the last couple months surfing these forums and drooling over the delightfully amazing creations. I have decided to be a spectator no more and use these hands to create a portable SNES using the ZN-40. I came to this case decision after two weeks of going back and forth between vacuum forming my own case or using the well suited ZN-40.

I am basically modeling LOB's white commisioned SNESp and using Ben's book as a guide for wiring and gutting and preparing everything to be stuffed into the case. I think everyone on these forums has amazing ideas and great products that they should all be proud of. Each day I spend portabalizing in the garage gets me crazy excited to finish my project. I will try to get some pictures posted ASAP for feedback. Thanks for all the inspiration!

[Life of Brian]

I'm glad you're taking the plunge! The ZN-40 is great because you have plenty of space inside to fit everything, but it doesn't feel too big. A word of warning - you are in for a lot of of sanding if you are attempting the "apply bondo to make enough space on the front for the controls" method. However, it's worth it. Just a lot of work.

[Demonmisfit]

Thanks LOB! You were right. Lots of sanding with more to go. I'm posting some worklog photos tonight. Would love feedback/comments from anyone. I'm still wondering about the controls. I saw a post on here previously about how/where to cut up the SNES controller but am wondering if it's easier to do Ben's blank board method and wire them in. Anyways, here goes...

Working on the case


Finished dismantling


Soldering iron vs Ben's book

[Demonmisfit]

I was scared to plug it in


Eureeka!!! I'm a mad genius!!!


I saw that LOB was able to shave some of this board off. What end is easiest and how much can I take off without killing it?

[Life of Brian]

Soldering iron vs Ben's book

I have done the exact same thing! Not on purpose, of course.

[ShockSlayer]

Ben's book, the bible of the portable religion.

Nice work so far!

SS

[Demonmisfit]

So I took off from work early to go out on my jet ski. Drove by the river on the way home and saw that it was real windy choppy! Not the other boaters choppy that makes jet skiing fun but the annoying wind in your face throwing the boat around choppy. So I came home and did the next best thing; portablized for a few hours.

Did a lot of work on the case. Got the layouts in and applied a ton of epoxy. Things I learned tonight:

1. When LOB says there will be sanding, THERE WILL BE SANDING!
2. Epoxy putty can and will give you chemical burns on your finger tips.
3. The soldering iron is your best friend and your worst enemy. I gotta pick one spot for it and remember that spot. That thing is freakin hot!

[Demonmisfit]

Pictures - The front of the case. I'm dreading the next time I have a few hours to kill cause I know they will be spent sanding this down. The putty in the opening is cause I'm a dremmel noob and really tore up the top. I plan to sand it down and make it cleaner.


Got the shoulder buttons in. I want to keep as much of an original "feel" to this as possible and am trying to use original parts. Had to kill 2 controllers to get it just right!


Also trimmed down the PSOne screen's mother board. Credits to the awesome forums and their infinite knowledge of all things portable.

[Zeturi]

Awesome work. Is this your first time modding stuff? I've just started messing around (and epically failing) with a Gamecube.

[XCVG]

Nice so far. I haven't done that kind of sanding, but I heard you shouldn't breathe the dust. Also, get some smaller wire, that stuff you used on the screen is huge.

[eurddrue]

Nice so far. I haven't done that kind of sanding, but I heard you shouldn't breathe the dust. Also, get some smaller wire, that stuff you used on the screen is huge.

I use 12 gauge all of the time (especially for power), that looks like 18-20. He'll be fine.

[AfroLH]

Nice so far. I haven't done that kind of sanding, but I heard you shouldn't breathe the dust. Also, get some smaller wire, that stuff you used on the screen is huge.

I use 12 gauge all of the time (especially for power), that looks like 18-20. He'll be fine.

Yeah Me too...


Oh, We are talking about wires


But anyway, very nice looking case so far.

[Demonmisfit]

So I did a lot of the case work last night. It was more sanding than I ever care to do again. I also went out and bought a smaller guage wire for the controllers. Anybody who can actually rewire the controller board after cutting it up into sections is ok in my book. I could not for the life of me get them wired. I exposed the copper so the solder would stick but they are so tiny. I guess I will have to keep practising to build my soldering skills. I will get more pictures up later today after work.

I also do not recommend using the sanding technique I utilize. I think I have pneumonia from breathing in toxic fumes and bondo dust, *cough*. You guys are real professionals. I see a lot of safety warnings throughout these posts. Even though I'm not the kinda guy who heeds those warnings it's awesome that you guys post that kind of stuff for people.

[XCVG]

Now I have a really stupid modding idea. It's- A SANDING PAD WITH A VACCUUM (SIC?!) CLEANER!

Anyway, that sucks. I didn't have any trouble wiring a controller. You need to scrape off the coating and use thin wire, like 26-30AWG. Ribbon cable will work, Kynar wirewrapping wire is better.

[Shakespeare]

I think I have pneumonia from breathing in toxic fumes and bondo dust, *cough*. You guys are real professionals. I see a lot of safety warnings throughout these posts. Even though I'm not the kinda guy who heeds those warnings it's awesome that you guys post that kind of stuff for people.

I'd buy a mask to prevent it from getting worse (if you plan on continuing this project while sick). It doesn't need to be fancy, just something to block or filter out the dust from sanding. While you're at it, go ahead and get some goggles too - you may look like a dork, but you won't be getting your eyes filled with grains of plastic and epoxy.

Love the case so far. With a lot more sanding to make the button areas flush with the case, it'll look awesome.