**Warning in advance**
The classic NES case has VERY little ventilation. In retrospect I should have opted for a low wattage "green" CPU. It does get very warm in there without a dedicated fan at the rear or something. I will probably have to install a metallic grate at the back to keep it from overheating. Right now it does fine as long as the Nintendo cartridge door remains open in the front, but adding the disk drive puts it a little too far on the warm side again.
The final product
For starters here is what the empty NES case looks like after the main components have been removed.
I kept the controller plugs in case I need to mod them later into USB ports accessible from the front. I kept the power and reset buttons as well and modded them so they still worked with the new computer. The rest of the inside needs to be dremeled out so all the new components can fit.
Step 1: Plan the build
Room is going to be tight, so you need to plan where everything will fit. I decided to place the mother board on the right side of the case so the back shield would match up with the old holes for power and hopefully leave enough room for the power/reset button board to stay so I would have less work later.
Step 2: Dremel
Dremel out all the unneeded plastic. This build is tight for space and I need the motherboard to be resting as close to the bottom as possible.
I saved the bits to use for later.
Step 3: Cut a hole for the back panel of the motherboard and secure the back panel shield
I have seen some people dremel out a hole for each component. That seems stupid to me. Instead I matched the back plate to the NES. The back side is the PERFECT height for a standard mini-ITX panel if you cut off the top frame.
I then superglued it on so it would hold tight.
The hole on the right is for the power cord.
Step 4: Attach the power supply
The picoPSU power supply looks like this. The 24 pin adapter plugs into the motherboard and the other end is secured to the case.
Step 5: Attach the motherboard
Because there is a giant hole in the bottom of the case, I wanted the mobo to be elevated slightly so I used the old plastic I had cut out of the case to create little half centimeter stands that could be superglued to the case, then screwed to hold up the mobo.Add the motherboard and this is how it looks with everything inside.
You can see that space is really tight. The power/reset buttons actually cover the USB 3.0 header. I was a little sad but I ended up not even using it so not a big deal. The SS hard drive is attached on the right.
Step 6: Mod the power buttons
It was super important to me that the power buttons work properly. I used an old power button from an old PC (visible in the background and on the left below)
I then dremeled off the back of the light blue casings. When you push the power/reset buttons, it extends a little plug in the back of the housing. I simply super glued the PC buttons to the back of the NES buttons. When you push the power, it pushes the PC power. Then I tied the PC's LED light to the NES light. It is orange which is annoying, it should be read, and I might try rewiring it later.
Here you can see the side and top view of what the buttons look like.
You could accomplish this with a soldering iron and some resistors or something, but I didn't want to go there and just opted for a mechanical solution. In retrospect I wish I would have moved the motherboard over to the right even further to allow for a little more room.
Step 7: Attach the slim disk drive
This part is ghetto. Laptop disk drives don't really have convenient screws to hold the drive in place. I need to construct a mount to hold it, but haven't figured out an elegant solution. For now, it is held on with duct tape, that starts to slip slightly when the HTPC heats up.I love the slot fed disk drive. The opening is just large enough for a dvd disk without problems. Other mods I have seen that have the traditional opening disk drive have to cut ugly holes in the front to make it fit, and they look awkward. The slot fed drive is a much more elegant solution. I love it.
You also need a specific cable to adapt the mini SATA connection on slim laptop drives to the 4 pin power connector.
Problems and things left to finish
- Heating is still an issue. I need to add a fairly large ventilation hole, preferably in the back of the case so I never have to worry about it overheating.
- I want to change the orange LED to red.
- Mount for the disk drive.