Description

We are no longer stocking kits.  However, the USB hub and HDMI adapter can be purchased from the following links:

USB Hub

HDMI adapter cable or from Amazon (more expensive)

 

Kit includes:

• HDMI cable
• USB hub
• Port bezel
• Custom NES Label

Does not include Raspberry Pi or NES cartridge 

Bezel made from ABS plastic. May include slight imperfections from the 3d printer which may require some light sanding or filing.

Installation notes:

USB Hub:

The USB hub has a switch on the side.  The switch should be set to the “OTG” position.  The male connector from the USB hub should be connected to the Pi Zero’s inner USB port, not the power port (see product image).

Cartridge Modification:

You will need to cut out the plastic that forms the card edge connector slot.  Leave a small amount of plastic on either side to give the bezel a backstop.  You can test fit the bezel with the cables inserted to ensure you’ve cut out far enough.  Various methods can be used to remove the plastic.  We’ve found the best success using a rotary tool (e.g. Dremel) with a 90 degree angled cutting tool to cut out from the bottom.

The USB and HDMI ports must be glued into the bezel.

Preparation:

Optional but recommended: lightly sand the outside surfaces of the ports to help ensure a strong adhesive bond.

Clean the ports and inside of the bezel with isopropyl alcohol (isopropanol) to ensure the surfaces are completely clean. Don’t use “rubbing alcohol”. All alcohol labeled as “rubbing” in the United States contains additives which will leave a residue. Also, do not use acetone which will attack/soften the plastic.

Let the alcohol dry completely before proceeding.

 

Insert the ports into the bezel.  Make sure the orientation is correct before applying adhesive.  You don’t want one USB port to be rotated differently than the others. The orientation of the HDMI port isn’t as important and, due to the short length of the cable, it may be difficult to rotate it anyway.

 

Apply adhesive/glue:

We have two recommended options –

1. Super glue (Cyanoacrylate): Get glue between the bezel plastic and the port on all four sides. You can apply glue around the edges of the holes and tilt the part around to get it to flow under the bezel plastic. You should also apply glue from the back on all four sides.

Make sure the port is pushed down all the way into the bezel before applying super glue. The glue sets fairly rapidly and it will be difficult or impossible to reposition things once it does.

If the ports on the hubs you have are much smaller than the bezel was designed for (like there’s a significant gap on three or more sides), you can use baking soda to fill the gaps. Super glue reacts quite actively (gets really hot, be careful) with baking soda, sets almost instantly, and acts like a cement. It’s a good way to fill gaps as super glue on its own requires a tight fit to bond.

You could also try an expanding glue like Gorilla Glue, but we haven’t tested it – could be problematic.

2. Hot glue: Apply hot glue in the holes. Don’t add so much that it increases the height of the part because it might not fit into the cart. You may also add some to the back, but it might not be necessary.

 

Other adhesive options:

Other types of adhesives may also work, but we haven’t tested them. Obviously, the glue you use must adhere to plastic to be effective. A two-part epoxy that’s labeled for plastic would probably work great. Contact cement or a PVA based adhesive may also work.

With any type of glue you may use, the most important aspect is to maximize the amount of surface area where the two parts are bonded together. Cleaning and/or sanding the plastic around the ports will help ensure the bond is strong.

 

Additional:

You may want to secure the Pi Zero to the cart, but it isn’t strictly necessary – the tension from the cables seems to keep everything in place fairly well.  However, to secure it you can use double-sided foam tape, hot glue, or some other method.  Try not to cover large portions of the board, especially directly under the CPU, with foam tape or hot glue as it may cause thermal issues/overheating.

Some people may want to secure the cabling to the cart, typically with hot glue, however we don’t find that it’s necessary.  Due to the tension from the bends in the wires and pressure from the cartridge on either side, we can shake the cart vigorously and don’t notice anything flapping around inside.