DieselDummy challenge [WiP]

[DieselDummy]

I've been bouncing an idea back and forth in my head and I think it's time to share it. There are A LOT of exceptional builds here in the forum. All of which have taken much skill and time to complete. I've seen a lot of different fabrication methods which are all quite effective. While I am a huge fan of the 3d printing, considering the precision and time efficiency, I've been thinking about how this may not be an option for everyone. The hope of providing an example or inspiration, coupled with the incessant need to challenge myself, is why I've decided to do a GBpi3 build without it.
The challenge, however, will be a build which uses no hot glue and no 3d printing. (I might just be a glutton for punishment.)

The rules:
-must be a non-AIO
-no hot glue (I will attempt no epoxy as well)
-any custom parts needed (button wells, screen brackets, etc) have to be made by hand.
-power tools are permissible
-custom PCBs and screen surrounds are permissible (try to use from a sudomod member when available)
-case mods are to be done with styrene, existing ABS, and WeldOn only.
I have begun this challenge and I will tell you now that the fabrication time has been grossly underestimated. This project MAY wind up being an absolute disaster. However, I've decided to take the risk and make the progress public. After all, how can we learn from our mistakes without admitting them.
There are very few ideas/technologies in this build that are my own, and almost none of us would be here if it weren't for certain people. I will try to give credit where it is due but if I miss something/someone, please inform me.
If anyone would like to attempt this challenge as well, be my guest...and please share.
My parts list and any codes will be updated as the project progresses.

[DieselDummy]

So far the front of the case has been heavily modified to fit the also modified 3.5" TFT HDMI screen by Kuman (amazon.com). XY button wells and PSP1000 joystick bracket have been fabricated and installed. The screen dimmer button and support installed. Also I was planning on having multiple boot options, the details of which have not been finalized, so I am keeping the touchscreen option and have also modified and installed the stylus.

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[ThompsonTinkers]

Ooh, I like the stylus. Very palm pilot!

[DieselDummy]

Ooh, I like the stylus. Very palm pilot!

Haha. All that effort to get it in there and it will probably be used twice.

[CrogDog]

Can't wait to see how it turns out, wishing you good luck! I had some success with my recent build using plasticard/sheet styrene to make custom parts

[DieselDummy]

Can't wait to see how it turns out, wishing you good luck! I had some success with my recent build using plasticard/sheet styrene to make custom parts

That's what I'm using 1.5mm styrene sheets and WeldOn. It works surprisingly well, and the best part is the ABS from the shell will weld right o the styrene parts.
Do you have yours posted? I'm gonna creep on it now.
This is what I'm using if anyone wants to know

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[VeteranGamer]

a really interesting build....

looking forward to see the progress of this....


just a couple of queries....

the HDMI port swap to the Ribbon cable, have you tested this (does it work, and how well) and how is the other end....




also is there a reason the crystal is dangling around...


.

[DieselDummy]

a really interesting build....

looking forward to see the progress of this....


just a couple of queries....

the HDMI port swap to the Ribbon cable, have you tested this (does it work, and how well) and how is the other end....




also is there a reason the crystal is dangling around...


.

Yes, the HDMI port does work it all has been tested. The other end on the pi 3 is the same as well. I had to do all of that to get the clearance I needed. I followed your second build for a while and saw the troubles you had with the HDMI ports. I am going to give you a credit in this for sure, just haven't gotten that far yet. Your work on your second build provided me a lot of information and certainly saved me a lot of time in trial and error. The crystal is dangling for clearance as well. It was just a tiny bit too tall for what I'm trying to do. I will go into more detail with this as the project progresses but so far everything has been tested and works which is why I decided to continue with the install and publication of this thread.

[VeteranGamer]

Yes, the HDMI port does work it all has been tested. The other end on the pi 3 is the same as well.

this is really a nice touch (top job)
theres no need to credit (thanks), i'm most probably gonna pinch this anyway.....


really looking forward to the progress of this build now.....


.

[DieselDummy]

i'm most probably gonna pinch this anyway.....

Have at it, it's a really good solution and I haven't had any troubles with performance. I do have to warn you though, it was a hell of a task getting it mounted securely and soldered on without any bridging. The connector on the pi looks a lot better and I will post pics and the parts details. The ribbon and connector are actually 20pin while the HDMI is 19pin, so careful attention to detail is a MUST when installing.