Worklog Xii-Boy V2 - Xenii's second portable Wii

[Xenii]

Hello everyone
This is the worklog of my second Wii portable: The Xii-Boy V2.
After finishing my first portable Wii, I was bored, I had nothing to do after school
So I decided to make a Version 2 of my Xii-Boy design...

So what is the goal of the V2 ? - Make a better and open source Xii-Boy !
Here are some flaws I want to fix with the V2:
- Add a 480p 3.5 inches screen plugged in VGA. ( will be much better than the actual 240p one )
- Add 4 custom PCBs ( instead of my random 3D printed pieces )
- Maybe add the Bluetooth module ( could be great in games like Skyward Sword )
- Fix some other small problems

I'll try to update this worklog as much as possible


So, let's start !
First, I started to replace my "random 3D pieces" by some custom PCBs...
The Xii-Boy has two fixations in plastic for the triggers: 1x for the Z buttons and 1x for the R and L buttons.

Here they are
So, I wanted to replace them by custom PCBs
I started with the simplest: The LZ / RZ PCB ( the left one in the picture )
Then, I placed the components, and wire them up !
And this is the result after maybe 1,5 day of work

Yeah, this is the first time I used Kicad... So I'm pretty slow

After that, I just put this PCB in my 3D design...

Then, I started the second custom PCB: the R / L PCB
Here is the schematic

I used the TMHF07 dual tact button. Thanks to @Y2K once again for the footprint !
( And yeah the connections for these buttons are wrong in that case. But I corrected it )
After one other day, this PCB was done !

I put a little 7 pin connector... You'll see later for what it will be used for

Once again, I put this guy in my design and...

It is actually in the RVL PMS... A bit worrying...

To fix that, I started the "DRILLING OPERATION"
and here is the result after "digging" the triggers:

This is much better !

I don't have enough time to continue my worklog right now... I'll continue it tomorrow
So yeah, thanks for the help, have a good day and see you next time

 

[Xenii]

Hello everyone !
This is the part #2 of the Xii-Boy V2 worklog !

After digging the triggers, I modeled the DS lite membranes for the Dpad and the ABXY buttons.

Then, I printed some tests and finally add the membranes in my design

I've also corrected some problem the V1 has. For example, when I press the A button on the side, it sometimes gets stuck... With my last edits, the problem is almost done ! And with a little bit of sanding I think it will be much greater !
I've also removed the old fixations for my old buttons PCBs made in test board

After that, I ordered the DS lite buttons, the membranes and the screen !
For the screen, the commonly used is the "Wisecoco 480p 3.5 inches" at ~ 65 CHF ( 71.18 USD ) ( Here is the link: https://de.aliexpress.com/i/4000079736318.html )
But, by searching a bit more, I found exactly the same screen but at ~ 35 CHF ( 38.86 USD ) ( Here is the link: https://de.aliexpress.com/i/1005005389582535.html )
I don't know if this screen is a scam or not. The seller looks legit, and the screen had one sold. So for the low price, I tried to order it...

I'll see in maybe one week if it was a scam or not

Then, I'm currently making the schematic for the 2 others PCBs. I'll finish and order them when I'll receive the buttons and membranes to test the felling.
If it's good, I'll make a sketch, export it in DXF, import it in Kicad and make the PCB...

So actually I'm waiting for the buttons and the membranes.


If you have any question or recommendation, don't hesitate to ask / tell me
I'll maybe use the laminated screen that @supertazon recommended. But for that, I have to order the driver board only. And the Wisecoco one is at the same price as the full kit at the other seller...

Thanks for the help and the encouragements
Have a good day and see you next time !

 

[Xenii]

Hello everyone
Welcome to the episode #3 of the Xii-Boy V2's worklog !

Few days after posting the episode #2, I received the DS Lite buttons and membranes !
The painting isn't perfect but it isn't too bad

After some 3D adjustments, I finally got a very nice feeling.
Unfortunately, I don't have a DS Lite to compare, but it feels good. And so much better than the V1.

Then, I started to prepare the case for the "Controller PCB"

I modeled the shape of this PCB and its fixations.

After that, I had to change the fixation's hole of the two first PCB (L|Z and LR|LZ)
The first version of those had a 1.4 mm hole's diameter. It's perfect for my screws... ...when they are screwed in the plastic case. But it's really too thin on a PCB...
So, I decided to change those to add a 1.9 mm diameter. (Exactly like the RVL PMS or the GC+ 2.0)
Here is the result:

I've also received the new screen ! It wasn't a scam
Here is the link: https://de.aliexpress.com/i/1005005389582535.html

Then I finally began the PCB Controller.
I had to create my own footprint for the DS Lite membranes.
I started by measuring the diameter of the contact pads on the membrane's side. (3mm)
I made a little schematic of what it'll should look like.
Here it is:

And here is the footprint finished:

The pad 1 and 2 are connected to GND and the 3 and 4 are connected together to the "DATA" Line.

And after a few days, the schematic of the PCB Controller was done !

I also wanted to add a rumble motor. But I didn't have the place, so I decided to change a bit the shape of the Controller PCB.

Right now, this PCB isn't done at all. I'll finish it soon
My first idea was to put the RGB LED at the same position as the V1. But this is not very optimal.
I'll put it on the top side. And this little change let me the place to put the rumble motor just under the PCB Controller !
Just like that:

I've also modeled the new screen and the screen driver board.

On this board, I will try to remove the biggest capacitors, the HDMI connector, the crystal, the power and menu button's connector.
I just asked @GingerOfOz if he has the references of the 2 components he changed (small capacitor and crystal) on his beautiful Wii Boy Color.
If I got them, I will be able to make the BEST upgrade on the Xii-Boy: The thickness.

Here are all the components seen from the left.

As you can see, the 240p screen driver board is very thick. But not the new one
Here is the same picture but with the new screen and screen driver board:

And this is what I could have if I can get the references of the @GingerOfOz's smaller components:

(Yeah the picture is on the right side this time... Sorry)
But anyway, I can minimize the Xii-Boy's thickness from 31 mm to 26mm !

Here is another picture of what the Xii-Boy V2 could look like.
And its name will probably be changed to Xii-Boy Pocket... Because it's actually 16% smaller than the Xii-Boy V1. And ~25 from the Gboy Rev 3.
I didn't find the Wii Boy Color's dimensions to compare. But If someone has them, you can tell me

So the case isn't ready for this big change, I'll do the modification only if I'm sure that I can replace the screen driver board's components.

So yep, Thanks for the help and the encouragements
Have a good day and see you next time

 

[Xenii]

Hello everyone
Welcome to the episode #4 of my Xii-Boy V2's worklog.

Few days after the posting of the episode #3, @GingerOfOz answered me. (Thanks once again )
So, I'm happy to say that the Xii-Boy V2 will lose 5mm of height ! It will be the Xii-Boy Pocket
I've modified the case for this change.

I've also removed all the old fixations.
This is before (on the current V1)

And this is after (now)

After that, It was time to make the Controller PCB.
I've made a reference sketch to know where put the membrane's pad or other components.
Here it is:

15 minutes after, the pads were placed !

And, after a few weeks / months, it was finally done !

Thanks a lot to @YveltalGriffin and @Y2K for their help and advices ! I'm very grateful
As you can see, I've put a lot of connectors. The P2 goes to the R / L PCB for the triggers, the P3 and P4 to the Left and C stick and the P1 will be connected to the Main PCB.
Finally, there are 4 test points on the top and 6 on the bottom. The top ones are to power on the screen, and the bottom ones for the speakers and the rumble motor.

Speaking of the Main PCB, Here is the schematic: ( not done )

It will be on the top of the Xii-Boy V2:

It will also have two connectors for the Bluetooth and the Wifi modules

Then, I added the 2 more fixation for the case on top. This was a problem of the V1 so it should be much better now.

I've also corrected other problems the V1 had.
for example, I've modified the Power and Volume - / + buttons. They were way too small.

I decided to move the RGB LED on the top side. It will be much better. Thanks to @supertazon for the idea !

I've also upgraded the cooling setup. (but I don't have picture)

After that, with the advices of @supertazon, I decided to use the laminated screen. The same the Wii Boy Color II has.
I wasn't sure about the appearance the Xii-Boy V2 will have with that screen.
So, I decided to model that screen and see what looks better.
Here is the V1 (normal screen)

And here is with the laminated screen:

I think the laminated screen is sooooo much better. I'll order it soon.


If you remember, the V1 had no Bluetooth or Wifi. For the V2, I wanted to add only Bluetooth. But I decided to use Wifi too !
Soldering Wifi is tricky though. But, @supertazon and @YveltalGriffin made a very nice flex PCB for the WiFi: The WiFI Flex !
The problem is: I don't have the place to put a Wifi module where the WiFi Flex is.
So, I decided to make my own flex based on the WiFi Flex !
And after many days here is the Xii-Flex !

It contains the WiFI Flex, the GCC, the USB and the 12S data lines.
All the data lines go to a FFC male connector I've designed. With this connector, I'll be able to connect my flex directly to my next "Main PCB" through a FFC female connector.
Once, again, Thanks a lot to @YveltalGriffin for all his help and advices. I'm very very grateful
He also suggested me to add a diode to my Controller PCB for the MP jumpers. So I did !

I think this is all for this episode. If you have any idea to upgrade the Xii-Boy, don't hesitate to tell me
Thanks a lot to every person who helped me. I'm very grateful
Have a great day and see you next time !

 

[Xenii]

Hello everyone !
Welcome to the episode #5 of my Xii-Boy V2's Worklog.
This one will be shorter than the older one, but I wanted to show my latest work !

A few days after the episode #4, I ordered the @supertazon's Laminated Screen. (Link here: https://a.aliexpress.com/_EzwvzFb)
And two weeks later, I receive it !
Here is a comparison between the Laminated Screen and the old 480P screen:

And now a comparison between the Xii-Boy V1's screen and the Laminated Screen:

As you can see, this is soooooo much better !

After that, I had to adapt the case for the new screen.
I've first modeled the screen:

And finally put it in my case:

And after a few tests, the final result: (V1 on top)

It's perfect

I've also worked on the Main PCB
First, I finished the schematic:

Then I started to place the components.

And start the routing !

I've also added the USB data line traces. With the help of @YveltalGriffin, I successfully add them.
He said they must have 90 Ohms impedance. So I did !

This PCB is a 4 layers board. The two external one are for data. The second one (In 1) is a big GND plane. And finally, the third one (In 2) is for the voltage polygons.
Here they are:

After many hours / days / weeks, I'm happy to say that it's finally done !

This PCB contains:
- A miniaturized U-Amp (based on @Gman's one)
- An USB-C 12V Power Delivery port (for the CHARGE)
- An USB to uSD converter
- A 17 pins FFC connector (to connect the Xii-Flex)
- Another 10 pins FFC connector (which will be connected to the Controller PCB)
- Four side buttons (Power, Volume -, Volume + and SYNC)
- A RGB LED
- And finally, a Bluetooth + WiFi module connector.

I've also corrected some mistakes the other PCBs had.

I'm also happy to say that all the Xii-Boy V2's PCBs are done !
I just have to check that everything is ok.
And If it is, I'll order them !

That's it !
Once again, If you have any idea to upgrade the Xii-Boy, don't hesitate to tell me !
Thanks a lot to every person who helped me. I'm very grateful
Special thanks to @YveltalGriffin for his wonderful help.

Have a great day and see you next time !

 

[Stitches]

Damn that laminated boiye looks good!

 

[Teatimetim]

Those pcbs are going to make for such a clean build!

 

[Xenii]

Hello everyone !
Welcome to the episode #6 of the Xii-Boy Pocket (V2) worklog.
This episode will be even shorter than the previous one

Well well well. I have something to show you

I've ordered them last week, and I'm proud to say that I finally receive them !!!
It took me 3 months of design. I've never used Kicad before.

Unfortunately, There are some mistakes on the Main PCB about solder mask.
The issue isn't really hard to correct, I just have to scratch the solder mask.

Once again, I wanted to thank everybody who helped me
Special thanks to @Y2K for some footprint, @supertazon for his general advices and @YveltalGriffin for his endless help
Also, big thanks to @Gman, @Aurelio, @supertazon and @YveltalGriffin for their wonderful open-source PCB (RVL-PMS, U-Amp, GC+ 2.0 and WiFi Flex)

I've also ordered the components through Digikey. I should receive them soon.

So where is the project progress now ?
Well, the longest part is done.
I will start the funny part soon: ASSEMBLY !
When I'll receive the components, I'll assemble the PCBs and then test them.
Next, I will be able to hack and trim a Wii and once again test it.
For the case, I'm working on the case every time something important happened (a new PCB to implement, etc)


If I have to give a number, I think the project is at 60% now.


By the way, the Xii-Boy V2 should be black with white buttons.

What do you think about it ?

That's it !
Once again, If you have any idea to upgrade the Xii-Boy, don't hesitate to tell me !
Thanks a lot to every person who helped me. I'm very grateful

Have a great day and see you next time !

 

[Mr Game & Cube]

Is there a reason you're using the old PMS and not the new one?

 

[Xenii]

Is there a reason you're using the old PMS and not the new one?

Good question.
Yes, I still have some PCB and all the components to remake one for free

 

[DekuNut]

Damn this looks good

 

[Xenii]

Hi there !
Welcome to episode #7 of the Xii-Boy Pocket's worklog !

First, I wanted to say that the mistakes about solder mask on my Main PCB came from me and not from JLCPCB.
So, what's happened ?

When I was designing this PCB, I did modify the side button and the USB-C connector footprint. I wanted to expose a little less of solder mask. Unfortunately, I did remove a bit too much Result: I could see the pads in KiCad, because of the solder paste layer (HASL in my case) but there were no solder mask holes under them.
I didn't know this could happen, and KiCad said nothing in the DRC. I'll be more careful next time

A few days after the episode #6, I received the components from Digikey.
I've also ordered some pieces and components from Aliexpress.

With the components, I did start the assembly process of my custom PCBs !
I've started with the two simplest: the LZ / RZ PCB and the L / R PCB. On this last one, there is a 7 pins 0.5mm pitch FFC connector. It was the first time I solder something like that. It went well !
Here they are:

As you can see, I did make a mistake (once again) with the R / L PCB. I did place the two dual tact button with the view set to the incorrect side. Result: They were reversed. I had to correct that with some small copper wire. It's ugly, but it works, and that's what matter the most

After that, I started the second most complex PCB I've designed for this project: The Controller PCB !
The soldering process went well, and the programming too ! It was time to test it. On this PCB, I have to scratch a via to test the PCB. Or solder directly on the connector, but it's trickier in my opinion.

I've plugged everything to the Wii and.... ... the sticks don't work at all
I had some weird issues with them. I cannot calibrate them in RVLoader. I was a bit lost. I thought maybe my PCB is completely wrong, or the solder are bad.
And then, I had an idea: Why not test calibrating the sticks in the GC+ 2.0 configurator homebrew ?
I've tested, and this time, I was able to calibrate the sticks. After a few attempts, they work perfectly !
Unfortunately, the sticks are bad. Terrible feeling and terrible precision.

A week after, I received some new ones from Aliexpress. I took them in white to match with the Xii-Boy Pocket color prototype I've posted in the previous episode
With them, it works perfectly ! They are just perfect !

With this success, I was able to completely finish the Controller PCB. Here it is:

I've tested all the buttons: everything works as expected !
However, I have some issue with the rumble. When I press A + B in the same time in RVLoader controller tester, They start to blink and the rumble motor doesn't spin at all. Maybe I will have a better result with the 5V. I've only tested it with the 3.3V... If someone has an idea, lemme know

Then, I've received the majority of the Aliexpress components I've ordered. Except the copper plate for the heat sink. I'll see what's going on later.
I've also received the DS Lite buttons:

They aren't perfect, so I'll maybe send them to erase the ugly painting.

After that, I've started to assemble the most expensive PCB in the Xii-Boy Pocket: the RVL PMS from @Gman
After two days it was done !

I've tested it and it works perfectly ! All tensions are good ! I didn't test the RGB LED and the charge yet. But I think, if the PMS turns on, that means the microcontroller works. If it does, the RGB LED should work too. Same for the charge, the charge chip is working because the PMS turns on and shows all the good tensions, so the charge should work as well.

You might notice I never trim the Wii motherboard for this project. It was time
I've first relocated the U10 chip:

I've quickly tested it after that, and it's still working

Then I've traced the trim:

And then, start the trimming process
By the way, I've never trimmed a Wii before. On the V1, my brother did it for me

The trimming went well ! This is definitely not the prettiest trim we've never seen before, but I'm pretty proud of me for a first trim

With these both last elements (RVL-PMS + trimmed Wii), I was able to test it.
And.... IT WORKS !
I'm so happy, everything seems to work perfectly ! (I've quickly tested the USB and it works too)

The last PCB I have to assemble is the Main PCB.
I first started to assemble the 12V Power Delivery circuit.
It was tricky because I had to scratch the solder mask. It's a bit ugly due to my stupid mistake about the solder mask, but it works !

This chip is perfect: very cheap, very easy to use, works with both PD and classic 5V charger, and it only needs a 6 pins USB-C connector which is easy to solder. This is just perfect
I you wanna make a USB-C PD circuit, check this one ! It's a CH224K. I bought it at Aliexpress and it works well !

I should finish the assembly process of this PCB soon. Then, I will be able to solder a Xii-Flex on the Wii and finally test everything together ! If everything works perfectly, I'll work on the final case

I think this is all for this episode. I hope you enjoyed reading it !
Once again, if you have any questions or recommendations, lemme know !
Thanks a lot to every person who helped / advised me. I'm very grateful

Have a great day and see you next time !