Making/Modifying a USB Hub

I'm currently designing an accessory for my computer which will house 4 USB ports as a USB Hub.  The issue i've got is I need to be able to contain the whole USB Hub in an area that is only 22mm deep and 170mm wide.  

I've taken a cheap USB Hub apart to see what it was like and I have run into a few issues.

The main one is that the total depth of the PCB to the end of the USB Ports is 35mm, 13mm over the size I need. 
The next issue is that I need room to place a screw between the USB Ports, 2 either side.  These screws have a width of 3mm and a head size of 5mm.    Putting a hole like that in the PCB would break and short the connections.

Does anyone have any suggestions?

Picture of Making/Modifying a USB Hub
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caitlinsdad5 years ago
Desolder the USB jacks/sockets off of the circuit board. Just attach wire jumpers to extend it. I'm sure it's not the optimal design if you are concerned about signal loss/crosstalk etc but hot glue/epoxy everything to the case. You might be able to shave a bit off the circuit board if it still doesn't fit in your confines or mount it slanted in the case.
K20Evo (author)  caitlinsdad5 years ago
Thanks, hadn't actually thought of that. Means I can put the circuitry on one side and the ports on the other whilst keeping the height down.

I've also got what looks to be a power in port on the left (black box to the right of chip)
Do you think I can simply remove that without it affecting the circuitry. No idea why its there anyway as its a USB powered hub
Some of the USB ports on your PC may be non-powered, no +-5volts but still have the USB signals. Some USB ports/hubs can be externally powered with a wall wart adapter. In those cases like if you plug in a humungus external USB hard drive, it might take more power than the PC motherboard provides so sometimes they have a dual USB cord to suck off more power.
K20Evo (author)  caitlinsdad5 years ago
Makes sense. What gauge wire would you recommend to replace the solder connections?
If you have an old ribbon cable to cut up, you can use that. Thin wires should be ok since it is not high voltage. You want it small and flexible, any old earbud cables or ethernet cables to snip off?
K20Evo (author)  caitlinsdad5 years ago
I've got plenty of stuff like that lying around. Will give it a bash and put it to good use! Fingers crossed if this works - I'll throw up an instructable
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K20Evo (author)  caitlinsdad5 years ago
Managed to find a slim USB Hub, however will still need some modification to move the USB Hubs so I can fit a screw