Sega GameGear VGA Connector Jig

thingiverse

These are jigs that can be used to cut out a VGA connector hole in the Sega GameGear shell so the game can be upgraded to play on a TV. It works with OEM and RetroSix shells. There are 2 different hole jigs. One allows the VGA connector to be perfectly center and the other can be used it you want it off center. You only need to print one of these based on your preference. Per request I added a 2nd router template with a smaller gap between the VGA plug and the GameGear shell. I did not test this to see if the cable will seat all the way down. Try printing the DB15-3mmHoles versions if you are only using these templates on a few GameGears and you want to use fewer purchased BOM parts. The jig is sized for M3 screws to thread directly into the plastic and the hole guide takes the 3mm drill bit directly, removing the need to source the copper tube and heat set inserts. See the picture that shows both the jig and the hole guide. I have used these on 2 GameGears so far and can probably use them on more before the plastic starts to fail. BOM: 2 x M3x5 socket head screws, 2 M3xD5.0XL4.0 heat set inserts, 1 hollow copper tube 3mm ID 4mm OD, CA glue Tools: 3mm and 4mm drill bits, drill, dremel tool, dremel 9901 cutter, drill bit bearing (1/4" OD 1/8" ID), dremel cutter. soldering iron, 2.5 mm alan wrench, 1/8" ID drill bit stop collar. Instructions: prepare 3d printed parts: drill out the 2 holes on the hole guide with the 4 mm drill bit ( I just ran the bit in the holes by hand), using the dremel cutter, cut two lengths of the copper tube about 10 mm long. Work the cut tubes into the 4 mm holes of the hole guide, make sure they don't protrude through to the other side. Use CA glue to hold them in place. For the VGA template, use a soldering iron to install the 2 heat set inserts into the holes. Assembly: Install the hole jig onto the bottom part of the GameGear shell by sliding it over the bottom edge. It will be a very tight fit and you may want to rock it back and forth to slide it down all the way. Use the drill and 3 mm drill bit to drill holes using the copper tubes as a guide. Use slow drill speed. Once both holes are drilled, remove the hole jig by gently rocking it back and forth until it is free. Install the VGA template by using the screws through the newly drilled 3 mm holes from inside the GameGear. Using the drill and the 4 mm drill bit, drill a hole in one of the corners of the template. Install the stop collar on the dremel cutter and slide the bearing on it. Put the dremel in low speed, insert the cutter in the 4 mm hole you just drilled and use the bearing guide to slowly cut away the material. Once the material is removed, install the VGA connector. Use CA glue on the threads of the VGA connector bolts so the nuts don't come loose.