Basic instructions to case mod your ps2 with a window to give it that super-gamer effect.
Step 1: Decide on Your Design
***WARNING*** this mod to your ps2 will void its warranties and be permanent, so do not attempt this unless you are confident enough to tackle this project
This WHOLE mod is centered around a single design. If this is your very first mod to a console, or if you aren't very skilled with a dremel, you should consider a simple shape, such as a rectangle, circle or triangle. Simple shapes are MUCH easier to do than complex ones (obviously)especially if you rarely work with a rotary tool, such as a dremel. Try not to choose a design that exceeds your skill level. Simple designs look good, especially if you take your time. Something like this should be easy enough.
clear cd case
Design Template(detailed later on)
Another good instuctable using this method is Here
Step 2: Disassembly
Flip your ps2 over, and remove all screws with a philips head screwdriver. Don't forget the screws underneath the rubber pads. Remove these with a flathead screwdriver, or your fingernail. If you're a modder, you know the routine, and if not, should be simple enough...
Step 3: Mark the Design...
It is very important to mark the design correctly on your ps2, because if your marks are wrong,the cutout will be wrong. To mark the design, there are a number of options...first, you can hand draw the image full scale on a piece of paper, then use carbon paper to transfer it to your ps2 case, or second, you can use a template or printout of the design. I chose the latter way, because i was afraid my marks wouldn't be symmetrical, and my window would look cockeyed. Many other ways will work, but the two that i thought of off of the top of my head were these.(there's a lot of "of"'s in there, huh?) When you print out your image, cut it out using an exacto knife, scissors, or something sharp and shiny....or, you can use carbon paper along with the printout, and transfer it that way...however you do it, remember not to make it permanently visible, but if you do, make sure you have a way to remove it...Masking tape works well.
Step 4: The First Cut...
How you cut out the design is entirely up to you, because techniques differ from one person to the next. However you do it, take your time and do it neatly...
I used a dremel with a cut-off wheel, but these break often. I substituted it for a high speed cuttter wheel, and this works fine, as it is metal, not that ceramic feelin crap that breaks so often. The smaller the blade, the tighter the cut radius, but the longer it will take you. The larger the blade, the smaller the cut radius and less cutting time.
One technique to use is to outline the design using the lowest speed, as if you're going to engrave it, and then come back and cut all the way through.
Step 5: Protecting Your Insides...
Now that you have a hole in your ps2 case, it's time to add a preotective covering, while still being able to see through the cutout.
Clear strong plastic works well, such as acrylic, but if you're like me, you don't just have a panel of acrylic just lying around for such a purpose. A good alternatve to this is a simple cd case. it's clear, strong enough for this purpose, as ther'll be no weight applied to it, and is thin enough to add without interfering with the insides of your ps2.
Another good alternative is an actual cd, with the label removed.
Step 6: Clipping the Cd Case
To be able to use the cd case, it won't exactly fit inside snugly. I cut the corners off of one using the dremel, and simply hot glued it in place, but this is a bad idea; the hot glue is semi-permanent, and won't allow removal of the case, in case you want to do something new, like etch it. So, i suggest using small screws, probably sie 4-40, or 3-32, available at radioshack, to hold it in place. One screw per corner should be enough, but don't tighten it too much, or the case will crack, and ruin your best efforts.
Step 7: Yay...a Hole in Your Ps2
Now that you have your window mod added, admire your handiwork...if you want to, add paint or other effects to your ps2, such as led's inside to light up your new mod. I added green LED's and powered them from the usb port on the front, and it looks pretty sweet. I will post a new instrctable on this as soon as i can.