Worklog Yet, another portable Wii

[Shipyu]

For a week now, I've been seriously searching how to make a portable Wii.
After a lot of trouble finding how I'll power my trimmed Wii motherboard with the current chip shortage, I could have tried building a RVL-PMS1 but I'll instead wait for new stocks.
I've bought a black wii with 2 controllers, cables and nunchucks for 20€.

For the moment, I've got my Aliexpress parts list nearly done ! I've just waiting for some feedback before ordering all the things !
Here is the long list of links and descriptions :

Spoiler

For the tools and consumable parts :
- Magnet copper Wire, 0.3 and 0.6mm | link : https://www.aliexpress.com/item/4001159051676.html
- Precision tools for scraping traces / 3d printed parts | link : https://www..aliexpress.com/item/4000834074184.html
- Little screws kit | link : https://www.aliexpress.com/item/32921732072.html
- 22AWG silicon wire, i took 6 colors | link : https://www.aliexpress.com/item/1005001590476043.html

For the buttons, cooling, and electronic parts :
- Display 480p 800*480 TFT 7" | link : https://www.aliexpress.com/item/32840229823.html
- Batteries : Li-ion 18650 3400mAh, I'll take 4 of them because I want 3 to 4 hours of battery life | link : https://fr.aliexpress.com/item/32887423130.html
- Push buttons for shoulder buttons, power button maybe, and other buttons like +, -, start... I'm taking the vertical ones| link : https://www.aliexpress.com/item/4000544090602.html
- NDS buttons, not sure if I'll take them, I'd use the ABXY buttons | link : https://www.aliexpress.com/item/32926131359.html
- Li-ion metallic holders, not sure if i'll take them or use parts I already have | link : https://fr.aliexpress.com/item/32884289489.html
- Switch joysticks, i'll take 2 | link : https://www.aliexpress.com/item/4001268436536.html
- Speakers, I'll take 4 just in case and i'm taking n°10 | link : https://www.aliexpress.com/item/4000060961814.html
- 1mm copper plate I'll cut to fit between CPU+GPU and heatsink with either themal pad or paste | link : https://www.aliexpress.com/item/32840229823.html
- 35x35x7mm fan | link : https://www.aliexpress.com/item/4001047851068.html
- Custom heatsink I'll cut to 35x35x7MM - Rumble motors, 10x3mm pack of 10 12000RPM | link : https://www.aliexpress.com/item/1005003987941308.html

I still need to find out what i'll really be using as the controller inputs, I'm quite sure about the 2 joysticks and the shoulder buttons. For the shoulder buttons, i'd like to do 2 pressure sensitivity using 2 push buttons that are spaced out
I'll add 4layer PCBs : RVL-PMS-Lite, RVL-PD 2, RVL-GC2+ and RVL-AMP. I'll maybe need to create custom PCBs for a better cable management but if I even manage to get the wii booting that would be great at first

Tomorrow I'll receive my cutting tool for trimming my Wii ; I can't wait to do it !
I've already done the U10 relocation but I didn't try it because I need magnet wire to solder one of its foot to another part of the PCB.

 

[honigbrai]

I would remove the Gamecube Memory Slots before trimming

 

[CrazyGadget]

Trimming from the back is easier IMO, but that seems to be a hot debate. From the back, no need to desolder any ports, they won't get in the way. Plus, most of the hard trim lines are made from components / traces on the back.

 

[Shipyu]

Trimming from the back is easier IMO

I'll do trace lines on the other side also and i'll cut under the board where it's easier because of the presence of the connectors, but i'll mostly cut by above.

What do you guys think about the components list I made ?
I also have a question about the line of capacitors left on the board. Do I need to keep them? I've seen someone that removed them once.

 

[honigbrai]

- Batteries : Li-ion 18650 3400mAh, I'll take 4 of them because I want 3 to 4 hours of battery life | link : https://fr.aliexpress.com/item/32887423130.html

Please do not buy those batteries, they are used and rewrapped samsung cells

 

[Shipyu]

Please do not buy those bombs

Why do you call them bombs ? What criterias should I check when searching for Li-ions cells ?
I didn't take the cheaper ones and they've already been used by @Benge

 

[honigbrai]

Not the same cells, but the brand is the same

https://budgetlightforum.com/node/56542?page=1

 

[Shipyu]

Not the same cells, but the brand is the same

https://budgetlightforum.com/node/56542?page=1 View attachment 24191

Though it's the top-seller in all Aliexpress Li-ion cells. Further down the link you sent we can read someone who's telling that because these cells are so popular, bad people are sending fraudulent cells.
I'd have to find either antoher brand or another website for the cells.
I've got a couple FST 18650 2200mAh batteries that I took from good portable batteries. The brand looks really trustfull IMO because inside it's very well made and the battery has been given by EDF (local energy supplier in France ^^). I could use them to test the wii but the capacity is just a bit more than half what I'd like...

 

[Sunny]

IMO it's not worth it to shave a few dollars off of your BOM by going for cheap Ali cells. I've had a good experience purchasing from NKON.

 

[Benge]

Why do you call them bombs ? What criterias should I check when searching for Li-ions cells ?
I didn't take the cheaper ones and they've already been used by @Benge

If you whant great and not "li-bomb" cels, you can go on this DE website : https://www.akkuteile.de/en
The one I used from Aliexpress are fine, but you never really know what you got ...

 

[Shipyu]

I think I found the one : https://www.akkuteile.de/en/sanyo-panasonic-ncr18650ga-3-6v-3-7v-3500mah-plus-pole-flat_100676_1277
Its tests has also been quite good : https://lygte-info.dk/review/batteries2012/Sanyo NCR18650GA 3500mAh (Red) UK.html
Same for the datasheet : https://www.orbtronic.com/content/Datasheet-specs-Sanyo-Panasonic-NCR18650GA-3500mah.pdf
So I think I've got nearly everything I need !

 

[Conron]

Good luck man. Im just now in the starting stage of my build. Here's a parts list I found that sorta helps (for a G-Wii) https://docs.google.com/document/d/1B6B3_TuYIHX4Une15si8NtRjfz9oxBRdxez1jFi0FhY/edit

 

[Shipyu]

Here is my "final" BoM !
I'll take silicon insulated wires because they're quite resistant against fire, they're more flexible so it's gonna be easier to fit everything in place even if I won't be able to give them the shape I want.
For magnet wire, I'll have 0.3 and 0.6mm wire, I think that should be good for most of the times.
I already have a lot of soldering and precision tools so I didn't include them in the BoM.
For the cooling part, I'll use thermal paste, a 70x35x0.6mm copper plate, a 35x35x7diy heatsink and a 35x35x7mm fan. I'm taking wood screws instead of usual mechanical screws so that i'll be able to "dig" inside my 3d printed case holes.
For the controller parts, I'm getting a lot of tact switches, soft tact switches, NDS buttons, joycon joysticks... I'll see how I manage to do a great setup when they'll arrive.
The wii will have 4 3500mAh cells so it should have ~4 hours of battery life.

 

[Shipyu]

Trim done ! It wasn't too hard but I hope I didn't cut too much
I already sanded it and I'm gonna test for any shorts.

 

[Shipyu]

Looks good ! I think...

 

[Stitches]

Trim looks prety much perfect to me

 

[Sergio49R]

Looks good

 

[Shipyu]

While waiting for my Aliexpress deliveries to arrive and for 4layer's website PCBs to be in stock again, I'm starting to 3D model the parts in Fusion 360 so I can then 3D model the case

I just finished the Motherboard and the MX chip board

 

[Shipyu]

4layetech just have new PCBs in stock ! I order the RVL-PMS Lite, GC+2, RVL, PD2 and joystick breakout boards !
I'm finnaly done (I hope) with spending my money. It cost me a bit more than 300€ for now. I can't wait to receive them

 

[Shipyu]

Since nearly a week, I've been 3D modeling the parts and components... I'm starting to assemble them in Fusion 360 so I can make the case i'll 3D print. I already have the dimensions of the handled console.
For the active cooling, I'm using a small fan+diy heatsink+copper plate. I'm not sure if how i setup the cooling will work great from what you can see i fusion :
The PCBs are arriving very soon :p