Guide: How To Modify A Model 1 Sega Genesis (with pics!) - 56k Unfriendly!
*Before I begin, I want to thank the numerous people here on Sega-16 that have helped me in my quest to successfully mod a SEGA Genesis model 1, sparking a passion that has become my new focus in life. Without you all, I doubt I would have had the patience to attempt this project, and it's my hope that I can now pass what I've learned onto those that wish to follow a similar path. Thank you.
OK, so here we go...
This guide will teach you the basics on how to mod a Model 1 Sega Genesis with AV outs, S-video out, JP/US region switch, overclock switch, and finally, a halt switch. The model I'm using is a VA2, but I will explain any differences with further revisions as best as I can. That said, let's dig in.
This is the unit we will be working on today:
http://img.photobucket.com/albums/v4...201/Genny1.jpg
Step 1: Preparation
First, clear out a suitable workspace where you can strip and cut wire, solder, drill, glue, and carve comfortably. For this, I used an old dining table that we were going to throw out. Also, make sure you have proper lighting for the job - you will need to see in some tight spots on the Genny; you'll need good lighting to make out certain contact points on the console.
You will also need the following tools:
-Screwdriver set
-Soldering iron (~30w)
-Desoldering iron (~30-35w)
-Desoldering braid
-Painter's tape (1")
-X-Acto knife
-Wire cutters
-Wire stripper
-Electrical tape
-Piece of smooth glass to cut on (A picture frame is ideal).
-Ruler
-Glue gun
-Cordless drill w/ multiple bits
-Dremel or similar cutting tool
-Approx. 5' of stranded copper wire - ~28 gauge; CAT5/5e/6 is the best option for this.
-Fine point sharpie or similar marker
-Sponge or soldering station.
-Caffeine to keep your senses sharp. I use Coke Zero.
In addition to the items listed above, you will need the following components to complete the multiple modifications on the unit:
-(1) 5mm LED (whatever color/brightness you want)
-(1) Set of red, white, & yellow RCA panel mount 1/4" jacks (can be found at Radio Shack, Digikey.com, or various other retailers)
-(1) 4-pin mini-din female connector (I used Digikey part CP-2740-ND)
-(2) Single pole, double throw toggle switches (Radio Shack part number 275-613). Try to get the bushing (the threaded part) as close to 1/4" as you can.
-(1) Push on/push off switch. Make sure you don't get a momentary switch; this is for the halt switch and needs to have a locked on/off position (I used Radio Shack part number 275-1565).
-(1) 6.3v, 220uF aluminum capacitor.
-(1) 2N3904 general purpose transistor.
-(1) 75 Ohm resistor (value can be modified as desired).
-(1) 25 Ohm resistor (value can be modified as desired).
-(1) Oscillator for your overclock - I suggest 10-12 Mhz.
*Note - some processors will not work with a higher clock speed, while others work
just fine. You may have to experiment a bit.
-(1) Project board. Any size is fine - you'll be cutting it down anyway. Just get one you're comfortable working with.
Still with me so far? Good, because we're just getting started.
Step 2: Opening The Case
Materials Needed:
-Screwdriver set
Taking off the case is a relatively easy process. Start by removing the 6 case screws on the underside of the console shown here:
http://img.photobucket.com/albums/v4...1/ff50567d.jpg
Store the screws in a safe location for later - we will need them to reassemble the case. Now, flip the console back over and CAREFULLY lift the top of the case up until you feel resistance coming from the top center of the shell. This is the LED, and it's attached to a wire with bent leads to keep it in place as shown here:
http://img.photobucket.com/albums/v4...1/9b59774d.jpg
To get the unit open you will have to feel towards the top of the inside of the console where the wire and the plastic meet, until you can feel two bent metal wires, one on either side of the LED. Gently bend those down and straight, then wiggle the connector attached to the wire so that it comes off of the LED leads altogether. Once the top is removed, you should be left with this:
http://img.photobucket.com/albums/v4...1/ccab4a3f.jpg
Note the white connector in the center of the system attached to the red and white wires? That's what's attached to the LED on the top cover of the Genesis.
TAKE NOTE: In order to reattach a new LED properly, take note of which color wire is attached to each lead. One wire is longer than the other - this is called the anode. On my console, it's attached to the red wire. YMMV.
Inside shot of the top of the Genesis shell (the anode is on the left):
http://img.photobucket.com/albums/v4...1/11f357a5.jpg
Set the bottom portion of the Genesis aside for now - We're going to prep the top for modification.
Step 3: Preparing The Case, Part 1
Materials Needed:
-Smooth piece of glass
-Painter's tape
-X-Acto knife
-Fine point sharpie.
http://img.photobucket.com/albums/v4...1/b6ccdc9c.jpg
In this section, we will detail the procedures needed to prepare your case to accept your input jacks and switches. To begin, lay out your piece of smooth glass and adhere a ~6" strip of painters tape to it as shown here:
http://img.photobucket.com/albums/v4...1/4f2453f0.jpg
Then, section off a 5.5" strip of tape using your ruler and mark it off with the Sharpie. Cut off the ends using your X-Acto knife and the ruler as a guide. Then, going from left to right, mark off the following points:
1 - 0.25"
2 - 0.75"
3 - 1.25"
4 - 2.00"
5 - 2.75"
Now, going from the right side and working left, mark off the following:
1 - 0.50"
2 - 1.25"
When you're done, the tape should look like this:
http://img.photobucket.com/albums/v4...1/7af05c3f.jpg
Finally, we will need to draw an intersecting line 0.50" high to mark off the exact points where we will need to drill our holes for the jacks. The result should look like this:
http://img.photobucket.com/albums/v4...1/ae487f68.jpg
Moving forward, take the tape and carefully lay it against the top cover of the Genesis Console. When adhered, it should look like this (sorry about the flash):
http://img.photobucket.com/albums/v4...1/13b4ea32.jpg
Now, take your handy dandy X-Acto knife and CAREFULLY place the tip of the blade into each intersecting point on the painter's tape, twisting the knife to create a small guide point for the next step. If you want to have your jacks looking nice and aligned, then this step is a must.
http://img.photobucket.com/albums/v4...1/61c9c298.jpg
Up close shot of where to make holes.
Now, using the smallest drill bit you can find:
http://img.photobucket.com/albums/v4...1/25be6935.jpg
CAREFULLY drill holes into each of the guide points you made. This will make the next step much easier. By now, your case should look like this:
http://img.photobucket.com/albums/v4...1/d776f748.jpg
You can clamp the shell down to something if you have the proper equipment, but beware of scuffing/cracking it in the process. Personally, I didn't feel it was worth the risk. Moving on...
Using a 1/4" drill bit, widen the holes in the case using the guide hole as a starting point. The end result should look like this:
http://img.photobucket.com/albums/v4...1/5ab46774.jpg
My holes are a little off (it looks worse than it is due to the curvature of the Genesis itself), but the whole thing will look fine once the switches/jacks are installed.
Now, using a 7/16" drill bit widen the 4th hole from the left and the second hole from the right, as the jacks for these are slightly bigger. Here's a pic of the hole sizes; don't worry about the switches in this pic just yet - we'll get to that soon enough.
http://img.photobucket.com/albums/v4...1/ade4915d.jpg
That covers the preperation for the jacks and switches, next up is the LED assembly and installation.
By the way, if you're not matching up to what I'm showing you in this guide, feel free to drop me a PM. I can't guarantee I'll get you immediately, but I'll help out as much as I can.