Keeping as many stock connectors as possible—cutting PCB

[Cannikin]

I'm trying to keep as many original connectors as possible (power switch, power socket, volume knob, cartridge connector), but without resorting to hot glue to keep them in place (no offense wermy)! The stock control board already has all the connectors, and in the perfect placements!

So, I decided to cut the center out of the board to get back some of the space between that board and the cartridge slot behind it. The cutoff wheel for the Dremel worked AMAZINGLY well. I was seriously dreading cutting the PCB assuming that the cutoff wheel would shatter into a million pieces and then I'd have to resort to using a hacksaw or something, but this couldn't have worked better. It was like cutting through butter with a warm knife. Didn't smell as nice, though. Make sure to use a mask:

[Kilren]

Make sure to use a mask

Like this?!

Ha, just kidding. Definitely following your build though, a few of your improvements has my interest.

[Ganreizu]

What will you do after that though? What does that connect to/how do you use it?

[Cannikin]

What will you do after that though? What does that connect to/how do you use it?

It does two things for me: keeps all the connectors in their exact placement without resorting to hot glue, and gives me an easy way to tap into them for my own wiring—power from the power socket, on/off switch for the Powerboost from the power switch, volume control, and wiring from the cartridge connector to the SD pads on the bottom of the Pi. I think I'm going to be able to put the Pi right in the middle there, on the lower part of the cartridge slot back. I started the wiring earlier:

[Fleder]

Sounds really interesting! I am curious as to how this all fits together in the end.

[Synnth3t1k]

Make sure to use a mask

Like this?!

Ha, just kidding. Definitely following your build though, a few of your improvements has my interest.

Pardon my ignorance. But I've seen others and @wermy suggesting wearing a mask. What's so bad about breathing the dust from the pcb? I don't have any mask, but I do my cutting outside where it's well ventilated.

[crispy_tofu]

Dust from a PCB is usually some mix of fibreglass and resin, which really isn't healthy to inhale.

[Kilren]

Dust from a PCB is usually some mix of fibreglass and resin, which really isn't healthy to inhale.

While this is completely true, the amount (the measurement alone should give you a clue, parts per billion ppb) is so minute that it will have no significant or lasting effect. Now, the problem arises when you are constantly in an environment where you are subject to it. Think of it this way, one exposure to second hand smoke will not give you cancer or any other negative side effect, your body will have time to heal and not be overwhelmed. Constant exposure or lifetime exposure will do damage.

Now, there are a few things that you never want to be exposed to. This is not one of them. Wearing a mask is safe, and good practice (and good habit), but absolutely unnecessary for this.

If you do feel the need: Dust Mask

[Ganreizu]

Desoldering these old components so i can even cut this pcb is such a biiiiiiitch. :[

[Cannikin]

Cut the corners off the Zero and it nestles right in there!