Disclaimer: I, or anyone linked from this instructable, accept(s) no responsibility for any injuries or damages that may occur as a result of this tutorial. Anyone building this adapter does so at their own risk. That being said my hope is that you will find this Adapter as useful as i have.
Step 1: Tool List
-Drill with a 9/64" Drill bit
-Needle Nose Pliers
-Gun type Soldering Iron with plastic melting tip or a Rotary Tool with cutting disc will work too
-No. 0 Phillips Screwdriver
-No. 10 Torx Screwdriver
-Utility Knife or Safe Package Opener
-Pick or Flatblade Screwdriver
Safety Gear: Safety Glasses and a Multimeter
Step 2: Material List
Item 0 Obviously you will need a XBOX 360 Power Supply :)
Item 1 Needed is a some sort of Socket for a Lighter Plug, I bought a 12V Triple Socket adapter from Canadian Tire for $11.99 CAD.
Item 2 Yellow and Black wire that is thicker than most signal wire. I used some 16 gauge wire that i had sitting around. You can probably score some 20 gauge yellow and black wire from any blown ATX power supply or you could buy some from Princess Auto.
Item 3 Small heat shrink tubing for the switch connections which you can also get at Princess Auto.
Item 4 is a switch, if you don't have a spare slider switch in one of your parts drawers or on an old toy that can be salvaged you can always check out Radio Source (aka The Source by Circuit City, or Radio Shack in the US).
Item 5 is a XBOX 360 Female Power Connector from a 360 Mobo (motherboard). I know that everyone has at least one or two friends that have a RROD (Red Ring of Death) 360 Collecting dust in their basement or garage. Why not rob the power connector from it and use it for something useful!
Or you could always try repairing it (well not permanently in most cases), my friend and I found that after repairing many xbox's the method that lasted the longest was the simplest. And no it wasn't the towel trick!!!!
If it is unrepairable like mine (notice the GPU is missing...haha...long story) then it's time to Salvage all the useful parts and connectors from the board...like the power connector for instance :). If you don't know how to get the 360 open check this vid out.
If you don't want to hurt a XBOX 360 mobo, you could always salvage a female connector off an Intercooler which are going for less than 10 bucks on ebay these days.
Step 3: Open the Plastic Prison
Step 4: Take the Screws Out
Step 5: Pop the Top Off
Step 6: Remove Wiring
Step 7: Flux Is Your Friend
Step 8: Remove the Connector at All Costs!
-Use desoldering braid to wick up all the solder
-Use a Solder-sucker to suck up the solder
-Flood all the connections with solder and use a pick or screwdriver to pry the connector off while heating the connection
It all depends on what you have available to you and what you feel comfortable doing, and remember to wear safety glasses you don't want molten solder in the eye.
Step 9: Essential Info: the Pinout
Power is enabled when 3.1V is fed to Pin 7 when measured directly from my 360 motherboard. I have done further testing and found that ~1.5V to 5V will enable the power (aka the green light activates and you get +12V).
As a result of my testing i found that one can easily enable the power supply on by wiring a switch between the +5VSB and the PWR ENABLE Pins.
Step 10: Line It All Up
Step 11: Trace Out Your Lines & Holes, Then Melt Some Plastic!
Now use your plastic melting or cutting skills to make the space for your power connector wiring.
Step 12: Clean Up the Cuts and Drill Some Holes
Step 13: Test Fit the Power Connector Then Line Up and Trace the Switch
Step 14: Cut Out a Hole for the Switch and Install It
Step 15: There's a Time to Melt and There's a Time to Solder
The method i used to solder these wires on was to separate the copper conductors in half then bend one half around the outside pin on one side and the other half around the other outside pin and soldered them. I stripped the wire long enough to meet both parts back at the middle pin after they looped around the outer pins and i then soldered them together there.
You can now feed your Switch wires through the power connector hole in preparation to solder them to the connector.
Step 16: Solder the Signal Wires and Don't Forget Your Heat Shrink
The theory behind the switch is that the 5VSB and PWR ENABLE share a common GND connection within the Power Brick so all we need to do is supply 5V from the 5VSB pin to the PWR ENABLE pin and VIOLA! When the switch is closed the Brick's LED turns green and the 12V Supply is activated and when it's open the LED turns back to Orange and the 12V shuts down.
Step 17: Now Make the Two Into One, Solder, and Use Your Trusty Hot Glue
Now solder your yellow (12V) wire and the LED lead with the white sleeve to the 12V back plate and your black (GND) wire to one of the circular receptacles (They are all shorted together with the red wire so it doesn't matter which one you solder to). After these connections are soldered use some Hot glue to reinforce the wires to make sure your solder joints don't break free. You can also add some Hot glue to the solder connections you made on the Power connector and Switch to reinforce them too.
Step 18: Final Step, Close It Up and Test Er' Out!
As a safety precaution use an ohmmeter to test the resistance between the Back plate and any circular receptacle, it should read "open" or infinite resistance. If some resistance is present check your connections at Step 15 and look for any stray wires touching each other or one of your wires may have been pinched in closing the housing. If the power supply was fired up with resistance between the power wires the fuse inside the Brick may blow and it's not fun replacing that fuse.
Now Plug your Xbox 360 Power Brick into the A/C wall jack and the other end into the female Power connector on your adapter and turn the switch to the closed (ON) position, you should now get a Green Light on your Brick as well as on the adapter itself.
12V should now be applied to all your lighter sockets (Check with a Voltmeter if you want to make sure), if it works Congratulations on completing your Hack, i hope it brings you much joy!
If it doesn't work, try some of these suggestions:
-Check your switch with an ohmmeter to see if it is closing/opening properly
-Use your ohmmeter to check if all your solder joints are making their connections
-Plug your Xbox 360 Power supply into a working 360 to see if it is still functional
NOTE: This adapter is not fuse protected so try to use Lighter Plugs that have a fuse built in them and make sure it is the proper rating for the equipment you are powering up. The glass fuse built into the Lighter plugs are not only easy to change (just screw off the tip usually) but are also cheap to replace.