The KB2040 will fit very tightly between the two halves of the shell. Just three areas of the shell will need to be cut and drilled-out in order to both create enough space for the board and an opening for the USB-C port.
Shell Cuts:
- USB-C port opening. (top)
- Boot/Reset button holes. (back)
- Remove speaker bracket spacer. (internal)
To make this process easy, these two 3D printable jigs can be used.
Start by placing the top cutting jig onto the top section of the back half of the shell.
It will snap into place and the small arrow should be pointing upwards.
Make sure both sides fit flush within the grooves of the jig before cutting.
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Using angle cutter pliers, carefully trim off the plastic above the jig.
Optionally, the 9x3.5mm USB-C segment can be pre-drilled to ease trimming.
If cutting without the 3D printed jig, then start by trimming off 5mm of the tab in the photo below. Then hold off on cutting the 9x3.5mm USB-C slot until the final assembly.
After the KB2040 mounting step, the shells can be placed together enough to allow for markings to be made exactly where the USB-C port will passthrough.
The KB2040 has two buttons, reset and boot. Access to the boot button is essential for updating the firmware.
Also for this mod the KB2040 will fit so tightly that when screwed together the buttons will be pressed, causing the firmware to not boot.
So two roughly 3.5mm holes need to be drilled into the battery compartment for these two buttons.
Start by removing the batteries and then place the second 3D printed jig into the two lower battery slots.
With the arrow pointing towards the top of the controller, drill out the two holes.
If drilling without the jig, then start with the hole on the left. This hole will be almost directly under the existing hole by 1mm. Then hold a KB2040 in place to guide marking the position of the second hole.
The KB2040 will mount snugly between the speaker bracket and the battery compartment.
There is about 1mm of plastic that should be trimmed on the underside of the speaker bracket to avoid it flexing into the board when being reassembled.
Using angle cutters again, carefully trim away the plastic spacer on the underside that touches the speaker.
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