Finalman's Sony PlayStation 2 SLIM in a PC Case Mod

 THE IDEA

This mod is to develop a PS2 SLIM motherboard adapter plate and wiring adapters that are able to be transplanted between different PC cases.

NOTE: Will support motherboard revisions GH-032 to GH-035.

REASONS

1. Use a PS2 motherboard that has no case or missing case parts
2. Allow the motherboard exposure to more air rather than being in a confined space
3. Motherboard steel classis's rust and the rust particles fall on to the motherboard and cause shorts.
4. Easily change the internal motherboard clock battery.

PERCENT COMPLETE

80%

TASKS

Complete:

Create the PS2 motherboard adapter plate

Create the PS2 to PC case On button and LEDs wiring hardware

Create the Processor/s heat sink adapter hardware

Create the fan cable adapter

Create the VRM heat sink hardware

Not Complete:

Create the Hard Disk Drive adapter mounting hardware

Create the Rear IO port adapter

Adapt the power supply

Extras: (Not important so I might do later on)

PS2 MOTHERBOARD

Dimensions:

The PS2 motherboards GH-032 to GH-035 measure about:

Width = 140mm
Length = 205mm

ADAPTER PLATE

The purpose of the adapter plate is to combine the standoff holes from the PS2 motherboard and PC case onto the one plate.

Details:
The PS2 motherboard is to be mounted onto a custom made ATX aluminium adapter plate measuring 244mm x 244mm x 2mm thick which is the same size as a PC micro ATX motherboard.

Design:

I have designed hardware to work between the the PS2 motherboard and adapter plate.

Orientation:
The PS2 motherboard will be oriented so that the controller and memory card ports will be accessible through the PC case rear IO port area and the rear ports on the PS2 motherboard will be facing toward the front of the PC case.

Orientation.


Procedure:

I used the PS2 and PC motherboards as templates to drill the standoff adapter plate holes depending on the motherboard version. The basic process is as follows:

1. Clean the aluminium plate edges of any burs
2. Clamp the motherboard in place
3. Use a bench drill-press to lightly mark the standoff holes using the following drill sizes:

   3.0mm - PS2

   4mm - PC

4. Remove the clamps and motherboard

5. Drill the marked holes all of the way through using the following drill sizes:

    

   2.5mm PS2

   4mm - PC

6. Remove the burs from the drill holes

Example PS2 slim.

HINT: For the most accurate standoff hole locations in the adapter plate get faulty PS2 and PC motherboards. Then grind the motherboard bottom till all of the SMD components and protruding through hole component legs are gone and the motherboard bottom surface is flat. 

WARNING: YOU SHOULD WEAR A FACE MASK TO STOP INHALING PARTICLES THAT MIGHT CAUSE INJURY OR ILLNESS.

Grinded PS2 SLIM motherboard.

Grinded PC motherboard.

PS2 MOTHERBOARD

COOLING:

CPU - GPU - RAM HEATSINK:

I have used a 100x100x3mm thick copper plate and cut it to form the perfect shape for the heat sink base and I then soldered a heat pipe heat sink directly to it. The shape that you see is so that it does not collide with any surface mount components. Will fit both GH-032 and GH-035 motherboards.

Copper Baseplate.

Final heat sink.

NOTE: Due to the location of a voltage regulator module (VRM) on GH-035 motherboards the heatsink base-plate must sit on at least 3mm high standoffs above the motherboard to prevent a collision between the two.

NOTE: To prevent the motherboard bending under the pressure of the thermal pads / putty and stressing the solder joints I will hot glue 10mm (H) x 5mm (W) nylon spacers under the center of the CPU and GPU.

HEATSINK FAN:

I made the following adapter from a PS2 fan and a PC motherboard fan connector.

MOTHERBOARD VOLTAGE REGULATOR:

I have created a small heat sink to go onto the voltage regulator that normally sinks heat into the motherboards steel chassis. It is basically a 1mm copper plate in an "L" shape to avoid nearby components with a small copper heat sink soldered to it.

NOTE: GH-032 motherboards only have one whereas GH-035 have two voltage regulator chips that require cooling. One of the GH-035 regulators will sink the heat directly into the heatsink base-plate through a thermal pad or thermal putty.

GH-032 location.

GH-035 location.

NOTE: Due to the location of a voltage regulator module (VRM) on GH-035 motherboards the heatsink base-plate must sit on at least 3mm high standoffs above the motherboard to prevent a collision between the two.

PC CASE

Although my mod is not specific to an individual PC case I have chosen to use the....

POWERING:

Will be powered by the PS2 power supply placed inside of a PC power supply. The PS2 power supply will be removed from the plastic case beforehand.

PORTS

Controllers and Memory Cards:

Accessible through the rear IO port area. To make the ports perfectly centered within the IO port area it will be sitting on ...mm standoffs.

AV:

Optical Audio:
I will be able to use the following Optical adapter to suit. The PCI bracket cut-out was done by myself. This will be attached to one of the PCI slots.

HARD DISK DRIVE:

To be added... 

NETWORK:

I have then custom made an Ethernet PCI port bracket. I pulled the RJ45 port from an old laptop, cut the square hole out of a PCI bracket blank and soldered the port to the PCI bracket. I then soldered an Ethernet cable to the RJ45 port pins. This will be attached to one of the PCI slots.

BUTTONS AND LEDS

PS2 Power Button and Power LED to PC Case:

I purchased a few 8 pin ribbon cable to 2.54mm pin header PCBs. I then drilled the mounting holes into the adapter plate.

PS2 HDD LED to PC Case:

More to come....