Had to spend time reducing the daughter board that connects the controller to the DC board, as the case won't shut. Desoldered the ribbon connector from a spare board, wired it to the main one, relocated it; relocated the capacitor and LED and flattened the resistor and fuse. Hope this all works ok...
Going to try again at closing this case down, it isn't easy! One side shuts ok, the other not at the moment!
One thing for sure, hard to see how a DC portable could be much smaller in length, breadth or height.
Yes, DNT, I am concerned about overheating. Running an unmodded DC for a while makes the back of the console warm, however of course there are metal plates over the system and only one fan to keep the system cool normally. The saving graces in my system will be three factors: (1) 4 fans not 1 (including one to pull air out of the system). (2) DC board sits on perspex rather than the PSone board, so will help to keep heat away a bit and help with a bit of airflow. (3) most importantly, using 7.4v not 12v. As has been illustrated before, running the DC off 7.4v not only uses significantly less amperage but also generates less heat. This might make a significant difference.
The combination of more fans and less heat generated by the system due to lower volts being used, are the two factors I am relying on to keep this baby a success. There is only way way to know the answer, and that is by stress test, which I will do, and report the results.
