My goal here was to make a small sleek SNES/ Super Famicom using the motherboard from an early heavyweight SNES which provides S-video and superior audio with it having a separate shielded audio box. I began searching for an housing and found an 80's answering machine that fit the bill perfectly to fulfill my vision.
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Step 1: Fitting Motherboard to Housing.
Making the parts from the large SNES fit inside this case was pretty challenging to say the least. After many revisions & trimming of this and that I finally managed to make it work.
Step 2: Cutting Controller Ports
The controller port width just barely fit this housing as well. I had to trim some of the plastic off the side of it to get the ribbon cable to align with the connector & to make it fit properly. Once I figured out how it was going to be positioned I used a sharpie to mark where the port holes had to be cut out. I used a dremel rotary tool to cut them out removing a little at a time and testing the controllers to make sure fit was tight but not too tight. I then sanded them down smooth with 100, 150, and finally 400 grit sandpaper.
Step 3: Cutting Cartridge Connector Slot.
Getting the proper position for the cartridge port required me making a simple template. Once again as with the port holes I simply kept trimming a bit more plastic until the cartridge would fit just right.
Step 4: Cutting & Making the Super Famicom Logo.
I drew up a simple sketch of my vision for the SNES slim & figured out where I wanted to place the super famicom logo. I made a template and taped it down & meticulously cut it out using my dremel. I purchased some transparent flash cards at dollar tree for the red, blue, green, and yellow logo colors to glue under the logo holes I cut.
Step 5: Using JB Weld Plastic Bonder to Fill Seams and Gaps.
I filled all the gaps with JB weld plastic bonder and used it to secure the Nintendo logo which I cut from the old SNES housing to a spot where a rotary volume adjuster was on the answering machine. I then used sandpaper and dremel tool to smooth it all out.
Step 6: Getting Cartridge Connector Dust Cover & Controller Ports Ready for Paint.
I used 3 different shades of gray to give the system that classic nintendo look. The controller ports I simply used plastic q-tips cut in short pieces to use to slide over the port connector pins to keep spray paint from getting on them.
Step 7: Painting the Main Housing.
The paint scheme on this was pretty complicated & took several different maskings and paintings to achieve the desired result.
Step 8: Installing Cartridge Connector Dust Cover Flaps, Controller Ports, and LED's.
The dust cover flaps I robbed from a snes mini housing I had. The regular SNES one would no way clear the cartridge connector & this 2 piece one I just barely managed to get it to work. I used JB weld to secure the controller ports in place. The led's I powered from the 5 volt pin on controller port 2. Since I was using a red led and a white one there was no need for a resistor because 5 volts is what they required. I cut a small piece of cardboard and used double sided tape to place aluminum foil over it to use as a mirror to light the multi colored super famicom logo from the white led reflection.
Step 9: Adding Metal Decals, Making Snes Logo, Getting Ready to Close Unit Up.
I ordered a pair of metal decals from seller on ebay from Poland. They arrived to the U.S. really fast and I had them by the time I was ready to button up the system. I made a North American SNES badge logo as well since this console plays all super nintendo titles. Goal I was going for was slim with this console but at the same time retain all the great aspects the early SNES has such as S-video output and the separate shielded audio box which is suppose to be the best audio any snes offered. It was on the early heavyweight units such as this one and can be seen in rear right side beside heat shield. All comes in under the size of my hand so I consider my goal as being achieved.
Step 10: Side by Side Size Comparisons With SNES, SNES Mini, and Super Famicom.
These pictures will give a better idea of the size of the unit. Making the cartridge connector dust cover flaps clear the connector was difficult. At first I thought I was ok on it clearing but upon placing the top portion of the housing the flaps hit so I had to revise the entire console by trimming all the motherboard post down another 1/8". This in turn also led to me having to trim the front portion of the actual motherboard & the front lower casing center being careful not to cut through the front. After many trips back and forth trimming and trial and error I finally got it to fit. The problem was when I trimmed the mounting posts for the motherboard it lowered it to where the slope in the lower portion of the housing was hitting. I could only trim so much motherboard without cutting through the controller port leads & it was so close but thankfully it worked, barely.
Step 11: Super Nintendo Slim Complete.
Needless to say I was very happy after firing it up and seeing all was good. Hopefully it will provide me a pathway through many 16 bit worlds from the 90's.