Quick update on boards!
Board designs are finished and being ordered. Here’s a preview of them:
Board for relocating the upper and lower screens, as well as the left side buttons and potentially the volume slider:
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Next is a flex cable to make is so that I don’t need to solder around 80 wires to and from the 0.33mm pitch FFC screen connectors:
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This necessitates the removal of the original screen connectors.
I also needed to make my own flex to carry the upper screen signals through the hinge…:
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… And a PCB in the upper clamshell to connect the hinge flex to the screen and speakers, which I ended up making into a thin, rigid PCB instead. The DS line usually has the upper pcb and hinge flex combined, but I decided to split them up for ease of assembly and potentially reduced cost. This means I’ll need to get and solder an extra FFC, but I think this is worth it.
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Finally there are 2 more straightforward PCBs: One to relocate the GBA slot to move it forward slightly and another to do the same to the headphone/mic port and start/select buttons.
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I 3D printed the rigid boards and 2D printed paper dolls of the flex PCBs to check that they’d fit before ordering.
My paper doll of the hinge flex became pretty hard to work with, but I was able to get it through the hinge and see that it lines up with the connector locations on the upper and lower PCBs:
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I also checked that the base flex PCB lined up with the solder points on the DS lite board:
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It’s pretty hard to tell if everything is lining up because of how small the solder locations are, but it seems like things are in the right place!
I’m happy with how the boards look so far. Routing the boards with screen signals was challenging due to the number of nets, but I had a lot of fun with the artwork on some of the boards. I may need to come up with a 3D printed jig to help with lining things up before soldering.
My next update will hopefully be me testing the boards when they arrive.
Until then!