Pi Zero W: The Bluetooth addition to the W changes how one of the pins functions, so a different config.txt is needed. The one linked right now is for only the original Pi Zero, and a Pi Zero W one will come soon.
There are currently 52 Version 3 Kit (blue board) backorders awaiting shipment.
The blue boards are shipping. Look for emails as the labels are printed. I’m making really good progress. I’m processing orders from 2/16. A ton of orders came in on 2/15 and 2/16, and I’ve only got a few remaining from those days. If you need to know how many orders are ahead of you, contact me and ask.
I’ve made a guide below so you guys can get started. I’m focusing back on the Version 2.1 Assembly guide for a little while, but I’ll update this as needed to clear up and confusion you guys have. The software portion is still being written.
The Version 3 build is complete. Boards are shipping and people worldwide are building their own PSPi’s as you read this. I’ll continue to update the guide as needed, but the design and fabrication work is finished.
This build takes the PSPi into new territory. This majority of the time spent on this build wasn’t with a soldering iron, it was with schematic and PCB design. It started as a rat’s nest of wires in Version 2 and grew into the modular Version 2.1, and has grown again into a full all-in-one at the request of you guys reading this. Many of you wanted something you could build in an afternoon and that didn’t require a PhD in electrical engineering, so I spent the last few months building this. It does everything that the previous versions did, and includes a few new features that weren’t ready when those versions were made.
These features are included on the PCB:
LED Status Circuit for Charging and Low Battery
Raspberry Pi Low Battery Warning LED Circuit
Raspberry Pi Zero Audio Filter Circuit
Updated On/Off Circuit
Simple Joystick using LM339
Audio Amplifier Using PAM8403 (includes switch on left side to switch speakers on and off)
Lithium battery management (proper lithium charging, protection, and boosting to 5v)
microSD breakout pads
Holes to solder the Pi Zero directly to the board
Hardware Installation Guide
Start with a disassembled PSP. You’re going to need some of the old parts.
Attaching the Pi to the Board
Here’s how the Pi Zero gets installed onto the bottom of the board.
Secure it with clamps. Make sure the holes line up. It’s time to solder them together.
Some of you may be able to solder the boards together without these pins, but they do make the whole process easier.
Use something to prop the board so you can keep the pin protrusion small. Make sure they are only barely above the board, otherwise they will short out on the LCD bracket.
Start soldering the pins. So typically I only use lead-free solder and it usually works fine, but I don’t recommend it here. It just doesn’t do the job well enough when large boards like these are pulling the heat from your soldering iron. Please use safe practices when soldering with lead. Rosin flux also makes the process a lot easier.
Once you’ve soldered the top side, do the same on the bottom side. You can use clamps again to make sure the boards are pulled together.
Solder a couple to keep it all together, then start cutting off the excess pins using flush cutters.
Cut them as low as you can, but leave enough to solder to.
Half of the pins are soldered. You can see the shiny rosin flux I used to make the process easier.
Go back and do the same thing for the other 20 pins.
I did something for comparison here. The left side is normal leaded solder, and the right side is high quality lead free solder. The left side took about 30 seconds to do, and the right side took about 10 minutes. The left side was easier and came out much better.
Here is the bottom all soldered up.
One more important step. Use a rag and some rubbing alcohol (91-99%) to clean up the flux. It doesn’t make anything work any better, but it looks a lot better and is far less sticky.
Trim the Plastics
This plastic piece has to be removed from the PSP case to make room for the board.
Optional Feature – Headphone Jack
Install the headphone jack into the case with hot glue. This jack comes from the PSP’s old board. If you think you’ll have trouble removing it, you can also purchase one here.
Solder wires to the jack.
Optional Feature: External microSD Card Access
These holes are for the microSD card breakout. This allows you to relocate the microSD connection elsewhere on the PSPi. It’s not required, but it’s really convenient to be able to swap the SD card out easily.
This part definitely requires flux and lead solder. Squeezing a little solder paste into the hole before soldering makes it easier too.
Use an ohmmeter to verify the solder joints are good. The SD card pins match the unsoldered pin holes below it. When checking, skip the 4th pin from the right. The microSD has only 8 pins, and the SD has 9 because there are 2 GND pins.
Hot glue your SD to microSD adapter into the empty compartment on the left side. This isn’t part of the kit, so you’ll need to get one when you buy a microSD card.
Don’t fill the whole compartment or you won’t be able to slide the cover off to remove the microSD card.
Optional (but recommended) Feature: External USB Connector
Solder wires to these two pins on the microUSB adapter. This USB adapter is included with the kit.
Solder the two wires to these pads on the board.
Install the board, attach the white power connector, and slide the FPC-24 cable into the open connector.
Flip the black piece down to lock the cable into position.
Repeat the process for the left side controls and the FPC-10 connector.
Finish Connecting the Headphone Jack
If you chose to attach the headphone jack, then solder the three headphone wires to the board pin holes labeled H.L (headphone left), H.R(headphone right), and HG(headphone ground)
Finish Connecting the External microSD
If you chose to attach the external microSD adapter, let’s start soldering it up.
Solder a wire to each of the SD adapter’s 9 pins.
And attach the wires to the board. Isn’t that convenient?
Soldering the Speakers
Solder the left side as shown. Just strip the headphone wire back a little to expose it. Attach them to the -L and +S on the right if you want reduced volume (and reduced PWM noise), or to -L and +L if you want much louder volume (and more PWM noise)
And flip the left side control board into position.
Solder 4 wires to the joystick pads. Use some hot glue to secure and insulate them.
Solder the red and black joystick power wires to J+ and J-.
And solder green and yellow to X and Y.
Putting it Together
Install the LCD bracket. Make sure you break off the part that usually sits below the joystick. Just bend it back and forth a couple times to break it.
If your bracket is bent at all and you’re afraid it might cause a short circuit on the board, you can put some tape over the board to keep it insulated.
Install some screws
Install the LCD panel into the bracket. If there is a sticky pad on the back of the LCD, you should remove it (or at least most of it).
Install the control board at the bottom of the LCD.
Flip it upside down and install the controller board onto the FPC ribbon.
Solder wires for power and composite signal.
Solder the composite video wire to the pad on the Pi.
Solder the LCD power wires to the pads on the board.
Remove the stickers and plastics from the two batteries and solder them together.
Be careful with the batteries. They have protection circuits on them, but that doesn’t mean you can’t still cause damage by short-circuiting them
Put the top cover on and put the remaining screws into place.
Solder the battery wires to the board. Take your time doing this and make sure you don’t hook it up backwards. Bad things will happen.
The LCD controller position is close to the Pi, so it’s a good idea to use hot glue to keep everything secured and prevent short-circuits.
And here it is.
I look forward to seeing how you guys decide to build your own.
One final thing to note is that the system does run warm, especially if you’re playing and charging it at the same time, and the new Pi Zero W runs even warmer. It’s a good idea to add some vent holes in the back cover so the heat can be removed.
Software Configuration – This is a work in progress
Download the following files:
Extract the Buttons and Shutdown zip files and copy to the same boot drive.
More coming soon…