So, I've finally managed to find some time to assemble my RP in the OneNineDesign case.
This was V2, the first one was a bit trial and error, so I bought another case (under a fiver delivered!) and set about working on it today. I did purchase a 3mm white LED as the 5mm almost lit the room up-the 3mm is still bright but not as bad. I also purchased a set of diamond hobby files from Maplin for about £6 so I could file the edges of the holes I drilled. I also made sure to cover the unit in masking tape as it marks so easily, but also good for getting measurements right.
So, this is the case:
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Cut out for power:
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Switch and LED (lined them up with the audio output and HDMI to make it look a little more in line with factory cut outs):
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Here you can see the header pins bent down to allow the original lid of the case to go back on:
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And here are the parts I had to file off in order to let the lid sit back on as it should:
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All in all, I'm really pleased with the outcome. I was nervous about bending the pins on the ControlBlock, but I was so careful and it worked out fine: to look at it doesn't look any different from how it did originally. The wiring is quite fiddly and it is a kind of semi-permanent modification, but the with is only held in with hot glue so peels away easily, and the LED & it's retaining clip slide out easily should I need to take it apart.
I was a little concerned about heat, but running NES/SNES/Megadrive emulators it gets warm, only slightly warmer when running the N64, but if it gets too hot I just take the lid off: but so far, no issues.