M2Slim Install Guide

Step 7: M.2 SSD Cutout

Overview

Creating a large, clean cutout on the PS2 shell can be a substantial undertaking. This section aims to make this process as easy as possible using common hand tools or a more professional machine.The included 3D printed jig should be sufficient for most hobbyists make an accurate cut into the shell.The engineering drawing provides accurate measurements for locating the cut and instructions for workpiece holding.The rest of this section will outline how to make the cut with a Dremel and hand file.

Tools:

Required:

  • Eye protection

  • Dust mask

  • Dremel or similar rotary tool

  • Cut off disk suitable for plastic

  • Flat hand file

  • Craft knife (exacto, olfa snap-off etc).

  • Hot glue gun

  • 4mm and 6mm drill bits

  • Drill

Recommended:

  • Calipers or ruler for measuring and making marks.

  • Tweezers

Step 7.1       Align shell cut jig

  • Line up the hole and groove with the features shown on the top shell.

  • There should be minimal play once the jig is aligned into place.

Step 7.2       Secure jig to shell

  • Use a temporary adhesive such as hot glue to secure the jig while cutting.

  • Don't go overboard as you will need to remove the glue later.

Step 7.3      

  • Glue the other side while the glue is still warm.

  • Hold the jig in place to ensure it remains seated and aligned properly while the adhesive sets.

Step 7.4       Scribe cutout area onto shell.

  • Keeping the blade aligned vertically and pressed up against the jig make light passes along each side.

  • The goal is to create an accurate guide to follow when using the dremel.

Step 7.5       Place drill insert into jig

  • Place the insert into the jig as shown.

  • It is designed to be a tight fit so some force may be required.

Step 7.6       Drill 4mm hole

  • Drill through the case using a 4mm bit.

Step 7.7       Remove the jig

  • Remove the hot glue and jig from the shell.

Step 7.8       Widen hole to 6mm

  • Use a 6mm drill bit to widen the hole.

  • Take care to not apply excessive downward force on the shell.

  • Use a backing material to avoid damaging your work surface.

  • You may wish to flip the case over half way and finish drilling from the other side to avoid causing a blowout.

Step 7.9       Prepare to cut the shell

  • Move to a suitable workplace such as outdoors or a garage, the dremel will create a lot of fine plastic particles.

  • Clamp the shell to your work surface. Holding the shell is both dangerous if the disk catches and more likely to cause it to catch.

  • Use an appropriate disk for cutting plastic. A thin circular saw is shown but abrasive disks seem more common.

  • Follow manufacturer safety instructions. Eye protection and a mask is recommended.

Step 7.10       Cut the shell

  • Cut the far side edge as shown to ensure the cut does not angle outside of the marked area as it exits the other side.

  • The cuts shown have a generous margin from the marked outline. Use whatever feels comfortable to you but I ended up repeating this step as there was too much material to file away.

Step 7.11       Remove the plastic from the cutout

  • Use a blade pry and cut the plastic free from the case.

Step 7.12       Evaluate the cut

  • As previously noted you may wish to cut closer to the scribed outline than shown to avoid excessive time spent filing.

Step 7.13       Attach the jig

  • Reattach the 3D printed jig with hot glue.

Step 7.14       Remove bulk material

  • Use the file to remove large high spots.

  • Take care to keep the file relatively perpendicular to the shell.

  • Move to next step as you approach contact with the jig.

Step 7.15       Accurate filing

  • As you approach the final size of the cutout take care to file from the jig side only.

  • Use the jig to hold the file straight.

  • Avoid rolling over and widening the cutout.

Step 7.16       Verify cutout is complete

  • Admire your work and double check the cutout is finished.

Step 7.17       Deburr edges

  • Carefully remove any excess plastic with a blade.

Step 7.18       Remove jig

  • Remove the hot glue and jig from the shell.

Step 7.19       Mark out the area needed to trim plastic rib

  • Trim the plastic rib that was used for jig alignment to make space for the M2Slim board when assembled.

Step 7.20       Score a line along the rib

  • Use a spacer such as a coin to scribe a cut along the jig.

  • Repeat the cut until it is deep enough to snap off.

Step 7.21       Remove the rib

  • Use pliers to bend and snap off the rib.

Step 7.22       Clean up the cut

  • Use a knife to remove excess plastic and clean up the cut.

Step 7.23       Test fit the cutout

  • Place the PS2 internals into the bottom shell.

  • Align the upper shell along the front and drop down into place.

  • Verify there is ample clearance around the M.2 SSD connector.

  • Test fit an SSD to check clearance around the drive.

Step 7.24       Trim disk drive door

  • The tab marked with the red arrow must be removed.

  • The one marked with a yellow arrow is less likely to cause issues but should be trimmed.

  • Use a spacer such as a coin to score a line across the tab

Step 7.25       Remove the tab

  • Use a plier to bend and tear off the plastic.

Step 7.26       Assemble the top shell

  • Insert the door spring as shown.

Step 7.27       Install the disk drive door

  • Align the door hinge into place while maintaining pressure agains the door spring.

  • Angle the door part way closed as shown to allow the hinge to enter the shell.

  • Slide the door sideways to lock it into place.

  • Close the door.

Step 7.28       Insert door hinge brackets

  • Place the metal hinge brackets into their recesses as shown.

Step 7.29       Install door hinge screws

  • Install the screws as shown.