Sprayed and sanded...

I did manage to take a pic of the case after more shaping and sanding on my iPad, but I couldn't get it to upload to Photobucket, so I just moved on.

Here's where we are at now.

I went with this color. In retrospect, I should've taken a pic with maybe the cartridge cover in the original pink to show the contrast, but honestly, it does look good. 

A little closer shot of the front panel. This is after one coat of paint and wet sanded. 

The back. That's water in the battery compartment, left over from rinsing after the wet sanding.

I'm letting it dry for another day before respraying and final sanding and polishing. Already got 1500 grit sandpaper for the final part. Gonna go get polish to finish it up.

Getting closer. I think a week and a half should be good.

More case work...

Got around to sanding the PlasticWeld off from the case. Used a coarse 120 grit and finished with a 320 grit.

Both sides. Still couldn't get the top front part of the case right. I may have sanded too hard and put a little slope on the back. When it's snapped together, though, you can barely tell it's there. I'm sure after paint it'll be ok.

...Yup, a little more pink showing there towards the top of the case. Maybe it's worse that I can see, but again, I'll have to see after painting it. The holes for X and Y came out nice, as well as the hole where the hinge was before. I modified the LED indicator lenses so it'll look at least stock DSish. 

Stylus hole patched and sanded nicely.

DS card slot patched up. I tried to sand it just right, but it seems that there's the slightest dip around the edge. 

Using a 1/16" drill bit, I made the speaker holes. The original mod has the speaker placed roughly where the stylus hole is. I opted to have it where the DS slot was. Testing shows that it sounds a lot better there. When I improve the case work, I may also add holes at the top of the slot that I covered to force the sound out that way. 

I need to pick up a 2 in 1 primer and some 1000 grit sandpaper. As for the color...still don't know what to go with. It may just end up being white...boring, boring white... 

Patching up the case...

As much as I didn't want to do it tonight, my brain said otherwise. I'll just say it quickly with pictures.

...There's gonna be a bunch of sanding to get this right...

Insides. I may have to redo some of the plastic filler after the first sanding. 

The area near Slot 2 is so flimsy that I cracked it by accident. I hope this little bit holds.

I'm gonna have to get some sand paper from the auto parts store so I can get a really nice finish on this. I may end up painting this thing white...probably sell it off if I can get another semi-working DS Lite in the near future.

Slowly getting back into modding...

I bought a busted up pink Nintendo DS Lite. The major flaw with this one was that the hinge was broken. Part of the screen was hanging off...I think it was the part that the ribbon cable goes through for the top screen.

I managed to test it prior to buying it and it powered up just fine. I bought it with a plan to mod it into a Gameboy Macro....this was several months ago. I just now got around to messing around with it.

I swapped the battery from this hashed one and replaced it in my wife's green DS Lite. There was a charging problem with it, but a quick battery swap solved that nicely. It came in handy on our flight.

The only part that I didn't have to really start the mod was the 330Ω resistor. I was at the point where I'd just use a regular resistor, but I had nothing in the 330Ω range. Closest I had was 220Ω, but I didn't want to risk it. So, I ended up ordering some SMD resistors as per the tutorial.

Tonight, I managed to get some work on it done. I managed to remove the DS card slot since I'm not gonna use that anymore, soldered the resistor in place, and soldered one speaker in (not really worried about having 2 there). I took the battery out of my wife's DS temporarily for testing.

First test failed. It was because I forgot to reinstall the WiFi module back to the board. I've read that it's required since the DS's BIOS is on it...or something like that. After reinserting the module, I powered it up and everything came on. Tested a game in it and it works perfect. I didn't have the buttons in, but I'm pretty sure that they're ok.

I ended up trimming the case down and get it ready for plastic fill before calling it a night with the project. I've been searching online for color compliments for the pink that I'm stuck with. I'm looking at certain types of paint and I recall vinyl spray paints are good since it doesn't just flake off like regular spray paints do. There's limited colors for vinyl spray paints, so I may end up painting this thing white.

Stay tuned...