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how to make a ps2 flip top case
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cimbom
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11. March 2007 @ 02:25 _ Link to this message    Send private message to this user   
If you want to make your own flip top, follow these instructions carefully and you won?t go far wrong (hopefully you won?t go wrong at all!).

Tools required:
Dremel, drill or similar
Jigsaw or hole saw
Snap off knife or scalpel
Sand paper
Small file
Super glue
Sticky pads

First you need to remove your ps2 lid, turn it upside down and remove all of the cover tabs, then remove all of the screws, making a note of where they go, for when you replace the cover.



Then turn the ps2 the right way up and carefully remove the lid, you must tilt the back of the lid towards yourself slightly, then pull forward until it clears the cd tray front, then lift the left hand side up, keeping the button side as close to the base of the ps2 as possible and look inside the cover as you are lifting, so that you can see the ribbon cable that is attached to the reset/eject buttons, carefully place the lid next to the ps2 and remove the buttons (they just pull away).

You should now have your lid free of the console.
You will now have to make a template using the dimensions shown below.
**NOTE!!! the measurement below of 197mm should be 92mm**



Once you have your template, cut out the part in blue (in the picture), and discard it, you want the rest of the template because you need to line it up with the end of the ps2.
It is vital that you line it up properly



Once you have the template lined up, tape it in place and use a crayon or whatever you have that will leave a clear mark on the lid.
So it should look something like this



Now double check the dimensions, when you are sure they are right get out your drill!
Make a few drill holes on the inside of your marking big enough to take the blade of your jigsaw or hole saw, cut around the inner edge, allowing a couple of mm for cleaning up, refer to the picture below.




Drill holes .
Once you have the circle roughly cut out you can cut the straight parts out in the same way, using a jigsaw, hole saw or dremel, the front edge that meets the face of the lid will cut through with a knife, it?s thinner in that area.
Using a small file with a round and flat edge, and some fine sandpaper, take the plastic back to the line, it is a good idea to wrap the sandpaper around something like a cd-r tub, and run it around the edge, turning the tub back and forth as you sand, and use the paper wrapped around a flat piece of wood or something similar for the straight parts.

You should now have something that looks like this




Now you need to start on the flip lid.
First turn the lid upside down and place on your plastic sheet, then trace around the hole you cut out.
You should have something like this




Cut the shape out using a snap blade or similar type of knife, allowing a couple of mm again for cleaning, and make sure you snap off the blade when you feel it isn?t cutting to good, otherwise you?ll end up cutting yourself, or stuffing? up your flip lid.
Use the sandpaper again to clean the plastic back to the line, keep checking for fit against the lid as you?re sanding.
When it looks like this??..




?you can make the hinges.
To make the hinges you will need to cut 4 pieces about 1 cm wide by 2½ cm long, then you will need to carve out a groove that your wire will fit into, using a knife or small drill bit.




Now you will have to use some super glue to stick these to the ps2 lid and the flip lid.
Like this




And this




The best way to line them up is to just place the ps2 lid with the flip lid in position, upside down and then set your grooved pieces on the edge of the flip lid with the wire in position, then line up the other two grooved pieces on the ps2 lid to meet them, now mark the positions and glue the ones for the ps2 lid first, wait a minute for the glue to set, then put the wire in position, now glue the ones for the flip lid over the top of the wire, making sure that you don?t glue the wire up too.
When that is done, take the waste plastic that you cut the flip lid from and cut some pieces from the circular parts, about 1 cm wide to use as rests
Glue the rests here; you will have to cut around the button holder too





Now your lid should look something like this




Now you?re ready to cut out your disc holder.
Mark out a circle on the cd tray cover about 20mm from the outer edge of the flat ring that is on the top side of the cover (this may vary on different versions)




Using the same method of cutting as you did for the ps2 lid cut the circle out using your jigsaw or hole saw, make sure you leave a couple of mm for cleaning the edge.
You should now have this




Now clean up the disc you are left with, until it looks like this




Now take your double sided sticky pads and stick two together, do this four times, then stick them on the back side of the disc so that they make up an even square on four parts of the disc.




when you have that ready, put the lid back on your ps2, then put a cd in the tray. With the magnetic disc in its holder, put the disc that you cut out of the cd tray cover on top of the cd so that the magnet holds it in place, and centre it, then close the flip lid down onto it and press firmly, when you lift the flip lid back up the disc with the magnet in will be stuck to the lid, now just press it harder over the pads so that they are stuck well.
Now you?re ready to start playing your backups (using swap magic or memcard exploit).



source from:http://www.exploitstation.com/articles/flippy%20guide.php
Related links
For more PS2 discussion, please visit our sister site, Blasteroids.com
Read our PS2 backup tutorial & information package
 
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