Worklog [2026 Contest Entry] PSP XL - The "Cutlass"

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BEHOLD! I present to you the start of a contest entry worklog for my latest project codenamed the "Cutlass"
I started this project on 5/3 after returning home from a weekend trip. Whilst on said trip, my big massive man hands kept cramping up from my psp being too damn small. I presumed that the 2026 contest was coming any day now since previous years were announced in May as well. I've never really entered a contest before, so I got excited and knew exactly what had to be done.

Once I got home that night, I hopped on eBay and naturally went overboard. I ended up buying 3 broken psp 2000 consoles.
I might've smoked a little too much because I was NOT going to settle for any less than eyepet and invizimals support on this thing. So I also bought 2 "untested" psp cameras.
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Since I still had to wait for everything to come in the mail, I started planning out everything I would need to shove in the shell so I could start designing it. I decided to dig around in my misc. stuff bins to see what I had sitting around (trying to work on my bad habit of just buying more things instead of checking what I've already got).

Here's what I scrounged up:
- 7" aliexpress lcd
- psp to hdmi adapter board
- hdmi output switcher board
- a TI PTR08060 regulator module
- 2s black "red board" bms
- 18650 batteries
- a bag of spare psp parts
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With all of this, I was able to conjure up a general idea of what I wanted to do:
larger psp console w/ 7" screen, intact umd drive, external hdmi output, 2p2s 7000mah battery, and run everything off 5v using a PTR08060

I took measurements of everything I had lying around and started whipping up a shell design throughout the next week and a half. I thought using the original psp shape in the larger form factor would look kinda goofy, so I decided on more of a switch-esque shape but with a bit more edge to it B|
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Screenshot 2026-05-17 145055.webp


By the time I got to this point, one of the psp consoles had arrived. A pretty clean looking silver unit. I figured out it just had a broken LCD and otherwise worked fine. Perfect >:)
I quickly got to work disassembling it!

Screenshot 2026-05-17 173235.webp


The motherboard was small, but I started getting curious on if I could make it even smaller. I checked out a psp 2000 service manual I found and was able to work out a board trim after determining there was a decent chunk of the left side with nothing too important (click here to see the guide I posted)
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I also chopped off both sides of an original psp shell down to only the umd drive section, which I plan to mount into my shell design.
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Slapped everything together for a quick test with a spare lcd I had - motherboard still works & umd drive reads discs!
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More updates on the way! I've done a bit more planning of the shell internals and placed a couple of parts orders this past week. Stay tuned! :D
 
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I started this project on 5/3 after returning home from a weekend trip
For a moment I thought I had to deliver bad news, but then I remembered that Americans write dates incorrectly
 
Been hard at work the past couple days on the system for mounting & cooling everything in the top half of the case! The lcd driver board, 5v reg, and psp hdmi adapter I expect to all get a bit warm so I want to at least move a little air over them to prevent heat from building up.
For this, I've designed a separate cooling chamber that'll later be capped off to isolate these hotties from everything else. This whole assembly will sit on the back of the lcd panel.

Screenshot 2026-05-19 144126.webp


While all that stuff printed, I whipped up a 5v regulator with the PTR08060 (followed this awesome writeup that has all the required values layed out in a table)

Also desoldered the menu/game switch from the psp hdmi adapter so it would sit flat (will later be re-wired to an external switch).
For those who are unaware, the psp uses different display scaling for games vs. the xmb & umd movies. I'm no wizard on display tech, but from my basic understanding this is all done magically on it's own for the psp's weird internal 30:17 ratio screen, but doesn't translate the same way when outputting video externally. Long story short, we need this switch to be able to swap between the correct scaling modes on the fly.

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Here's a photo of my test fit with all the parts!
I think I'm going to opt for these hdmi breakout adapters as they'll be a bit easier to solder to / troubleshoot should anything need to be rewired later.
Still a lot of work I've gotta do with all this so I haven't actually fastened anything down yet. Feeling pretty good with this layout so far though!
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Very nice!

(btw you don't have to have the contest paper in every photo. One paper per major update is enough)
 
Very nice!

(btw you don't have to have the contest paper in every photo. One paper per major update is enough)
Thank you!
And oh okay! I wasn't sure how strict it was lol. Definitely makes things easier not having to make sure the paper is in there every time xD
 
All good. We made that distinction last year and I forgot to put it in the FAQ
 
A couple of updates!

I knew from the start that I wanted an external hdmi out on this thing. Though I was a bit on the fence on whether I should do a full docking mode or just go with how the stock psp did external display (using console itself as the controller).

After some thought and research, I'm happy to announce... WE'RE GOING ALL IN >:D
A day or two before my last update I ordered some of Stephen Cooper's open source PSP-Bluetooth boards via JLC assembly. I ended up ordering without the micro usb port or ESP32 installed because they were trying to charge me a huge extra fee on those.
Luckily enough, I already had a spare ESP32 in one of my parts bins, no idea what for, but I was happy to find it. Soldered that on and sacrificed a old micro usb cable so that I could program the board.
Then I hooked everything up for a test, and it works exactly as I hoped! In addition to bluetooth, the board also has solder pads for every button on the psp so wiring my internal controls will also be a breeze.
Huge thanks to Stephen for all his hard work developing this for the psp modding community!

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Smaller update, but I've been slowly working on the custom hdmi cables and had to show one off early. I used to watch a lot of ps2 modbo installs which inspired me to make the cables like this. I think I'm going to start using this method a lot more, very satisfying!
Just need more practice on not getting ca glue all over myself :facepalm:

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Today I made some tweaks to the mounting bracket for all the adapter boards and printed a finalized version!
I ended up finding a right angle mini-hdmi to hdmi cable that worked a lot better between the splitter and lcd driver than the ffc hdmi cable I was initially planning on using.

Did a bit of voltage wiring and temporarily connected one of my psp consoles to the hdmi adapter for a test run. Hooked it up to a 9v adapter and BOOM everything lit up (in a good way of course). Such an exciting point in the project seeing everything start coming to life! Been doing a ton of work on the case design over the weekend so I'm sure I'll have an update soon for that as well once I start doing some test fitting :D


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I'm really excited to see the case design I bet it'll look epic!
 
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