Kresent's GBC Zero (WIP, custom PCB, "frankencasing")

Show off your completed Game Boy Zero, or post your build logs here!
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Kresent
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Kresent's GBC Zero (WIP, custom PCB, "frankencasing")

Post by Kresent » Sun May 21, 2017 8:34 pm

I've been lurking for a long time and really dont want something as large as a DMG case. After starting with two GBA cases, I've finally have gotten the motivation to try again and actually do some frankencasing for this project. This time, I'm going to use a Gameboy Color case with a RPi Zero. I am also going to stick with the standard 3.5 inch screen. I decided to go with the GBC instead of trying the GBA again is that there is more room for the ABXY "face plate" to fit without impairing the shoulder buttons. I've seen a lot of people do their build with the Gameboy Pocket instead, but I've chosen the Gameboy Color due to the rounded battery pack, which I think will make the shoulder buttons more comfortable.


Anyway, here is the GBC. Instead of destroying my good GBC, I put the PCB into a different case that is in nicer condition and have opted to use this purple case for my project. My goal is to fit a 3.5 inch screen in there along with adding X, Y, L1, & R1. I've opted to do some case modification using "JB Plastic Weld", using the buttons and templates from a DSi. I plan to use "soft" tactile buttons for the d-pad and face buttons, though this might not work due to size constraints. I'm going with USB audio and GPIO buttons. I currently have an 2500 mAh battery that is pretty large, so I might look for something smaller.

Getting on with it, here is the original Gameboy Color. The pictures don't show it well, but there are a lot of scratches/chips on the shell along with the protective screen being very damaged. However, as is expected with frankencasing, I will be doing a lot of sanding and also painting, so these scratches are not an issue for me.

Gameboy ColorShow
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The first thing I tackled was fitting the screen. Measurements showed that the screen is roughly 7 mm shorter than the GBC shell, so I had to shave off some plastic from the sides to get it to fit. It's a tight fit, but it's in there and flat. This means that I'll have to relocate the power switch and volume wheel, but I am thinking about putting them in the Gameboy game cartridge. It might be possible to use the EXT. port for the micro USB breakout board.

After I was satisfied with the screen, I went on to buttons. I took all my buttons from a busted DSi I came across. Unfortunately, these buttons are designed to work with those tiny tactile switch membranes that are directly on the DSi PCB. I'm planning on using some "soft" tactile switches I have, but I have a suspicion that the button layouts might be the same as the DSi so I could possibly use the rubber pads. The start and select buttons will be standard tactile buttons. As I'm likely making my own PCB, I didn't want to have to mess with making such a small conductive pad for the relatively small original rubber pads.
Case Modding [FRONT]Show
NOTE: The screen is a broken one from my first GBA try that didn't survive disassembly. I'm using it for size testing
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Next on my list will be to do some cutting on the back of the case. I plan to cut out most of the battery pack. I don't think I'll need to do too much more to it other than figure out what kind of L/R buttons I want to use.

After that, I'll use the JB Plastic Weld to set the buttons in for the first time. Due to the width of the screen, some of it is now seen from the outside (as the volume wheel, EXT port, and power switch are indented). I'll have to use some of the plastic cement to fill those areas in and make the case look flat/smooth. Then the sanding and re-applying begins. I believe this step will take me a few weeks, due to the time it takes for the cement to cure and how much of a perfectionist I am. Another problem for the future is that I've managed to remove every screwpost from the front, so I'll have to remount all of those once the screen and button PCB are in place.

I've got most of the parts available. I really struggle with doing button pads so I don't know how long this project will take me overall, but I really want something smaller than the original DMG but I also want 4 face buttons + 2 shoulder buttons. I've basically already gotten my screen/pi/power strip/powerboost set up, so once the case is "complete" and painted, I can start mounting stuff and worry about audio and buttons.

Super wordy but any advice would be greatly appreciated!

Kresent
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Re: Kresent's GBC Zero (WIP, custom PCB, "frankencasing")

Post by Kresent » Sat Jul 22, 2017 11:41 pm

This got put on the backburner (was anxious about frankencasing and unsure if I wanted to commit to trying to use DSi buttons), getting the parts and finishing the MintyPi motivated me to get back to work on this.

Case molding on the front started. Planning to do a lot of work tomorrow on the back shell, along with a bunch of sanding on the front shell.
Case moldingShow
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Re: Kresent's GBC Zero (WIP, custom PCB, "frankencasing")

Post by muniosi » Sun Jul 23, 2017 7:30 am

Good work! I'm always intrigued by frankencasing.
I've just finished my milk.

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Re: Kresent's GBC Zero (WIP, custom PCB, "frankencasing")

Post by RxBrad » Sun Jul 23, 2017 9:16 am

I made a face that looked a lot like this before I figured out how you were patching those holes. Nice job.

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Kresent
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Re: Kresent's GBC Zero (WIP, custom PCB, "frankencasing")

Post by Kresent » Sun Jul 23, 2017 11:21 am

RxBrad wrote:
Sun Jul 23, 2017 9:16 am
I made a face that looked a lot like this before I figured out how you were patching those holes. Nice job.

Thank you! This is how the face looks after sanding. Applying another layer of epoxy to the power switch/ext port/volume wheel slots so that I can change their position (due to the screen taking up so much space)
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Unfortunately, my only Dremel is wireless and the battery is like 30 minutes max or something ,so I'll be slowly doing some work on the back case today while the epoxy on the front dries. Hopefully I'll be back tonight with more pictures/updates.


EDIT/
More pictures, backcase has been rough cut and pilot holes for the L/R buttons have been drilled. Not liking how the sides are coming along, might retry with some pieces of plastic so it can bond better. Accidentally knicked the side of the front while trying to make the screen sit better, added epoxy there to fix it.
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