First Build - Circuit Sword
Posted: Sun May 05, 2019 8:09 pm
Kite's marketing is spot on... that was an adventure. It had been a while since I tested my skills (and patience) with a project like this. My soldering iron had been resting comfortably in a tackle box I re-purposed during my college years to hold all of my electronics gear. But, Wermy's videos were speaking to me... and the Circuit Sword looked like just the thing to "scratch the itch" that had been building slowly.
When I started this project, the slightest misstep drove me nuts. Today, while I was taking photos to share... I realized one of the posts of my HoolyHoo bracket had sheared completely off from over-tightening. I just did some cleanup with my Dremel and epoxied the shit out of it. All fixed, no big deal. It would be nice if everything turned out perfect the first time, but I wouldn't have learned anything... and I "learned" a lot.
Some things I learned:
Here's the parts I ended up using after all of my research:
I got this case from Amazon and used a Flat Iron to create a well for the back buttons. Pretty pleased with the results.
Very happy with the final alignment on the screen. (This is the second top half I built. The first ended up enough off-center that I just couldn't live with it.)
I don't know why, but I love this little addition to the headphone jack.
Had to make room for the speaker and battery. (The foam tape keeps the battery snug.) Man, those stickers are really cool.
The insides aren't as pretty as the outsides, but I'm happy with how everything turned out.
More of the insides... Can you spot which post was broken?

When I started this project, the slightest misstep drove me nuts. Today, while I was taking photos to share... I realized one of the posts of my HoolyHoo bracket had sheared completely off from over-tightening. I just did some cleanup with my Dremel and epoxied the shit out of it. All fixed, no big deal. It would be nice if everything turned out perfect the first time, but I wouldn't have learned anything... and I "learned" a lot.
Some things I learned:
- Don't use epoxy until you've test fit everything... twice.
- Make sure your screen is exactly where you want it before epoxy comes anywhere near it.
- Be mindful of the Dremel. (Plastic scratches so easily.)
- Rosin makes for happy soldering.
- No, this is not the "last time" you'll have to take everything apart and put it back together.
- Yes, you didn't put the ribbon cable in straight again.
Here's the parts I ended up using after all of my research:
- Shell, Buttons and Pads from Retro Modding
- Screen Cover from Retropie Handhelds
- Stickers from YaYa Design
- Helder's MEGABAT
- Veco Speaker
- Cartridge from Hand Held Legend
- HoolyHoo Bracket
- Shoulder Button Bracket from Glitch'd Gaming
- HoolyHoo's Power Switch Bracket
- Eltoozero's Back Board Bracket
- DIESEL_DUMMY's Headphone Jack Collar
- PSP 1000 Joystick
- 3DS Joystick Cap
- Carrying Case
Circuit Sword in CaseShow

Modified Carrying CaseShow

Screen AlignmentShow

Headphone JackShow

Rear and BatteryShow

InternalsShow

Under the MainboardShow
