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Cyxty Four N64 portable

cy

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After >100 hours of 3d modeling, lots of test fitting and assembly work, and many other challenges, my first original portable is finished!

The Cyxty Four
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This portable was inspired by @Wesk 's Ashida Wii portable which took an original GameCube controller and "digitally frankencased" it. In other words, Wesk took a 3d scan of a GameCube Wavebird, stretched it, and turned it into a portable. This project applied that idea to the N64 by taking Wesk's Brawler 64 3d scans and essentially doing the same thing Wesk did. I didn't do anywhere near as good of a job as Wesk did with the original Ashida, but I'm still happy with the results and I plan to improve this build in a second revision down the road.

Here is a video I took of the Cyxty Four in action:

Here are some comparisons for yall:
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As you can see, it's not much longer than the original Ashida, and it's only a few millimeters taller because the Brawler 64's geometry goes a bit higher than the Wavebird's.

The bottom of the unit has a headphone jack, fan intake, volume wheel, battery door, and two switches. One switch toggles the controls between the internal controller and the breakout box's player 1 port. The other switch toggles the composite video signal off for the screen to keep the original signal's integrity when playing on a TV or CRT.
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On the top of the unit from left to right we have the following:
USB-C Charging port, USB 3.0 port (for the breakout box), Screen power button, Reset button, Battery indicator via RGB LED, and the power button.
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The breakout box supports video out along with 4 player multiplayer!
Here's what it looks like:
breakoutbox2.jpg

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It plugs into the aforementioned USB 3.0 port on the unit.

My video mentions the analog gate, but doesn't show a side by side comparison between my console and the original N64 controller, so here it is:
OEM Gate.png
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It is difficult to make out because the front part of the joystick is so big, but the analog gate works surprisingly well according to the custom Everdrive controller testing ROM.

It's internal time!

Under the motherboard rests two heatsinks, a 5 volt fan, the U-Amp, PMS1, Charging board, Volume Wheel, RGB LED, Power, Reset, Screen Power buttons and USB 3.0 port (which wasn't mounted yet when this picture was taken):
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(Don't worry, I used more thermal paste than what's shown in the picture...)

With the motherboard in place, you're not able to see a ton because of the electrical tape. You can at least get an idea of what's going on inside though. Mounting was done using holes in the motherboard, and brackets were used to ensure the CPU, RCP and RAM are all making proper contact with the heatsinks and fan. When I unavoidably had to unscrew and lift the motherboard once in this build, both heatsinks and the fan were very stuck to the RCP, CPU, and RAM, so I know they're all making great contact with the cooling solution.
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The front contains the screen, controller, speakers and nothing more. Yes I did resort to double sided tape and hot glue for mounting the screen driver board and controller PCB, but I wouldn't have been able to get a unit this thin without doing so.
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Keep in mind that these pictures were taken a fair bit of time before closing up the unit, so residual flux, bad connections, or any other problems you may see in these may have been resolved between the time of taking the picture and me actually closing the unit.

Something else I'll mention is that this console is undervolted from 3.3v to 2.8ish volts using a PMS1 that I modified with help from @Y2K and @YveltalGriffin . Undervolting increases the battery life, lowers the internal heat, and is better for the components in general if done correctly, so I thank you two and @Wesk sincerely for encouraging me and helping me to do this!

I also want to thank @cheese @CrashBash @Gman @Teatimetim @CrazyGadget @GingerOfOz @Shank @Wesk @Redherring32 and other members of the community for giving me feedback, advice, and other help with this project. This wouldn't have been possible without you all!
 

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cy

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Thank you! :D

I weighed the unit and it weighs in at around 1 pound 8 ounces. It is 58mm deep, 283mm long, and 105.7mm tall (although it's several millimeters shorter in the mid section). This is just in case yall were wondering the dimensions. As for battery life, I'm running a test as we speak.
 
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You nailed that brawler controller profile, looks amazing!
 
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cy

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Thank you both!

I just finished doing a battery life test on it, and using an Everdrive the console got 2 hours and 37 minutes of battery life! I'm willing to bet that without the expansion pak and using an original cartridge, I could get 3 hours! To me that's amazing especially for using only one 21700 cell!
 

cy

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Thank you all for the kind words!

I wasn't originally planning on releasing the files for this build until I streamlined things a bit, made another revision, and cleaned up the geometry. But after giving it a lot of thought, I realized it would be best to release them. The files in this release may not be perfect, and due to how abrupt this release is, there may be something I missed or forgot. But what I've provided should be enough for anyone to build a Cyxty Four without a ton of hassle.

Some things to note:

- The .3MF files in this release have been made to print on a Prusa MK3s+ and have not been tested with any other 3d printer.

- Some geometry on the outside of this build is a little rough, low-poly, and is overall garbage quality. This doesn't really impact the functionality or feel of the unit too much (at least, not in the case of my FDM printed version), but there's obviously things that could've been done better. This project was very rushed, and I wanted to get it done before my college classes started back up.

- Some geometry on the inside of the case is unacceptably rough from a cosmetic standpoint. This was done intentionally to save on polygon count given my modeling software's limited capabilities. Please note however that this should NOT impact functionality and will likely remain the same if I'm to make another revision.

- This build is NOT beginner friendly! I made an effort to update the cartridge slot to work with @Teatimetim 's cartridge slot flex, but this has not been tested, so it may not work.

- This build requires that some of the aluminum capacitors are replaced with tantalum capacitors of the same value.

- This build requires the jumper pak slot be removed making either @CrazyGadget 's Akira flex or an Akira method jumper pak relocation mandatory.

- The screw posts in this build strip a little too easily.

- This build requires a seemingly random assortment of screws to be used. I don't have exact measurements for each screw hole, I just made the screw holes "deep enough" wherever I was able to.

- A number of things in this build rely on hot glue or double sided tape for mounting. This was done to save on space.

- Video out and 4 player controller support was removed from these files in an effort to simplify the build.

- A little bit of post processing is required. Beyond removing the supports, fitment of the L button is a bit weird, and may require a bit of sanding depending on your print results.

- A rev1 Brawler 64 controller is required for this build. A rev2 controller WILL NOT work. This image shows the difference between rev 1 and rev 2 controllers:
rev1 vs rev2.png

The main differences between rev1 and rev2 is that rev1 has a circular area that sticks out around the dpad. Rev2 controllers do not have this, although rev2 controllers do have nicer Z triggers that can be swapped in over the rev1 Z triggers.

If you decide to build one of these, expect unprofessional, poorly thought-out, and overall bad execution with all 3d printed parts. This was a rushed project, and many things could've been done better.

I've attached the files for this built to both this post, and the initial post for this thread.
 

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cy

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Came out looking great!
Wow! This is really looking good! Something I forgot to mention is that I automatically set the front of the unit to print at 100% infill. This was done to ensure the unit has plenty of structural integrity. I believe it is probably okay to print the back at 15%, but I thought I should mention this. I should also draw attention to the method I used to make the joystick work.
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(don't worry, I cleaned up the flux afterwards)

I took one of these joysticks opened it up, trimmed it a bit, de-soldered the pot, scraped the copper out of the mounting vias of the retro brawler PCB, and put the pot through the two PCB holes with it mounting by being soldered to the joystick board. I found you need to be incredibly careful when de-soldering the pot from the joystick board, and I thought I'd draw attention to it here since is might not be immediately clear to anyone who wants to try their hand at assembling one of these.

Just something to be aware of. I didn't make a BOM for this build after all.
 

cy

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Something I forgot to include in my original post are pics of my RCP wiring, so I thought I'd show that here. I'm honestly not very happy with how it came out and may open the unit up to redo it at some point or just replace it outright with a flex. Anyways, here it is:
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For anyone who isn't aware, the RCP wiring is one of the things that allows the board to be trimmed down this small. It cuts off the original cartridge slot and replaces a lot of the tedious easy soldering with soldering that's tedious and tricky.
 
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