Sony PSP audio docking station

Some time ago, I got a Sony PSP by chance. Actually, my parents won it as a prize at a town fete. I am not fond of video games, but I like the PSP's capability as multimedia player (video, MP3 files and Wi-Fi Internet radio). Compared to most of the MP3 portable players, PSP is not pocketable but it has a large display and the handy control buttons make file browsing and playing very comfortable. When connected to a pair of amplified speakers, PSP is a convenient MP3 player for home use. Obviously, this basic setup (second picture) makes PSP owners jealous of iPod people, who have a large choice of stylish audio stations. Indeed, the Instructables community has produced a lot of

home-made iPod stations. I was inspired by this project for its style and finishing: http://www.instructables.com/id/Good_quality_iPodiPhone_speaker/ On the other hand, the choice of PSP stations is poor and strongly oriented towards gamers. Most of them are very small and deliver a sound that needs a bit more amplification than the built-in minispeakers (third picture) are capable of. That is why I decided to build an audio station capable of producing decent sound quality, by transforming a pair of amplified speakers in a small PSP audio docking station. Of course, the sound quality will strongly depend on the speakers employed in the project. What you need: Amplified computer speakers MDF or plywood board (8 to 10 mm thick) Wood glue and hot glue Paint Small drywall screws Sand paper Office drawing hardware: paper, set-square, ruler, pencil, and calculator Electric hardware: soldering iron, electric wire, electric tape, connectors, stereo audio jack Tools: electric jigsaw, minidrill ("Dremel") with some accessories, hand modelling saw, screwdrivers,

Step 1: Design
i

a handle could be integrated. not similar to any other market products. As for my previous instructable ( http://www. I like this features as it gives a sort of dynamic look. Obviously. the overall structure was designed inclined backward. After some attempts and sketches.instructables. I wanted my station to be original. Moreover. The form: I wanted to give the object a style that goes well with the PSP's rounded silhouette. for ease of carrying. I arrived to the design below: Step 2: Dismantle the speakers . Therefore I started with a rounded shape in my mind. design is a mix of form and function.com/id/Plywood-magazine-rack/ ). The function: The audio station should have a small footprint that can be placed anywhere.As I stated in my first Instructable.

All the parts. have been re-used in the docking station: .transformer . except the plastic case. Before disconnecting or cutting the wires. I labelled them and marked the positive contact of the loudspeakers. Step 3: Fitting the electronics on the case .electronic circuit board and sound controls . but a better sound would be obtained using better loudspeakers.loudspeakers I re-used the cheap original loudspeakers.A screwdriver is usually sufficient to dismantle the computer speakers.

.

.

.

therefore the width and height were determined by fitting all the components on the panel. I started from the bottom. volume. marking the position of the components and the holes to be cut for mounting. the first position of the switch panel was the left bottom corner. A rectangular hole was necessary to insert the circuit board in the sound station.In my draft design I planned to place all the electronics in the front panel. To make things easy. In the final version it was placed on the right. I trimmed the plastic panel to reduce its height to a minimum (pictures 3 and 4). tone. Loudspeakers In the original case the loudspeakers were mounted from inside. I kept the original plastic panel with all the electronics fixed on it. As you can see in the pictures. I used a cardboard box. and indicator LED) were fixed on a plastic panel and the circuit board was directly held by the control wheels. In my audio station I inserted from . which was also convenient for transferring the design to the MDF board. My objective was to keep the station compact. For simplicity. Electronics The original sound controls (on/off switch.

therefore it was not possible to calculate an optimal volume. the plastic case of the original speakers was very small and I thought that a slightly larger volume should have been beneficial for reproduction of bass frequencies. Step 4: Sizing the enclosure. This not a real hindrance. Panel list BK: back T: top . The wood material should also help to improve the sound. I sized the speaker enclosure. the volume of this box should suit the specifications of the original loudspeakers. PSP holder and audio connector I simply placed the PSP on the design and drew round it it with a pencil. The handle I designed a horizontal rounded slot just over the PSP for handy transportation. In this project the specifications of the cheap loudspeakers were unknown. It is L shaped and needed a slot cut for fixing it and letting the audio wire enter the case. This gave the perfect position of the holders and the audio jack.outside as this made the assembling easier. For an optimal sound result. These speakers required 70 mm holes. Anyway. After designing the complex front panel. since this is not a hi-fi system. The audio jack and its wire came from an old pair of headphones.

.B: bottom LR: side right LL: side left M: middle Step 5: Tracing and cutting the panels.

.I used 10 mm thick MDF for the front panel. The side and back panels were made of 8 mm plywood. because with this material it is easy to obtain very smooth rounded edges.

The front panel was traced on the MDF panel simply by placing the cardboard template on it (first picture). The side and back panels were drawn on the plywood with the help of a ruler and a square. I used an electric jigsaw to cut all the panels. The plywood could be easily cut with a hand modelling saw. but 10 mm MDF is a too dense for hand sawing! Step 6: Assembling the case i i .

i .

The first stage of assembly involves the side box panels. Take care the glue does not fix the box to the bench surface! Step 7: Finishing and sanding the panels. I clamped them together and trimmed the borders until the two panels overlapped perfectly (second picture) A thin layer of woodglue was spread onto the contact surfaces and borders. I checked if all the parts fitted well together (first picture). Before final glueing. The left and right panel were not identical. . The parts to be assembled were placed on a horizontal flat surface and tightened with two screw clamps and elastic bands (third picture). The back panel was put in the assembly but not glued. I separated it with an aluminium foil. It was in place just to help keep all the panels at the right place. To avoid glueing the back panel.

.

.

In this way these parts perfectly fitted the panel surface without any protuberances (picture 4 and 5).The upper back corner of the side panels was rounded using the jigsaw and sand paper (picture 1). Step 8: PSP docking i i . were also rounded and smoothed with sand paper. the case was assembled with the front panel. After the glue was properly dry. Two narrow vertical plywood bands were fixed in the inner surface of the side panel in order to form a frame. The edges of the side panels and front panel. An additional finishing step was to groove the front panel following the shape of the switch panel and of the metallic frame of the speakers. onto which the back panel can be screwed (picture 2). including the handle hole.

i .

i i .

The right stand could include the 5 Volts DC plug to charge the battery. In any case. The two stands were fixed on the panel with some screws to check their alignment and then unmounted for painting. Fitting the audio jack needed a hole in the front panel and a groove in the back side of the left stand. In this way it was possible to mark the hole to be drilled. The left stand includes the audio jack. This could be very convenient. the charging inlet remains accessible when the PSP is docked. Step 9: Painting i . which plugs into the PSP line-out when the console is docked. The PSP was placed onto the panel in its final position and the audio jack was plugged in it.i Two stands were designed following the shape of the PSP bottom corners. I did not include this plug in the box. because I preferred to keep the AC/DC adapter separated. A similar procedure was applied in order to mark the groove to be cut in the stand.

i .

The plastic switch panel was also painted taking care to protect the electronics from spraying. The red LED was protected with a small piece of modelling clay. Step 10: Mounting the electronics i .The whole box was painted with three layers of gloss white spray paint.

i .

i i .

i i .

i i .

the two speaker output wires and power input from the transformer to the amplifier. I screwed the switch/control panel. They include the input stereo wire. The transformer was then fixed on the bottom panel using hot glue. The power cord was passed through the back panel by a hole and blocked with some glue to prevent it being pulled it off the box. all the wires were connected and soldered. The audio jack needs to be firmly fixed since it is pushed and pulled each time the PSP is docked. After closing the back panel the sound was okay.I started by screwing the docking stands. Before going on. Before closing the box. . It still remained to dress the naked loudspeakers. The AC input cable of the transformer was terminated with a screw connector. I performed a rapid test to check if it worked! For a final finishing touch the heads of the visible screws (switch panel) were carefully hidden with small circles of white adhesive tape. After soldering. If the jack is loose you can use some hot glue to fill the small gap.

Step 11: Speaker cover i i .

i .

i i .

i i .

I put it in place and marked the position of the speakers and of the outer screws. transparent but fragile. I used an electric screwdriver. because the rotary tool turns too fast. but very slow. I drilled a dense grid of small holes (2.I designed a speaker cover with a shape similar to the PSP. Eh! Eh! If you love DIY. As raw material.5 mm diameter). To allow sound to pass through. therefore drilling all the holes took almost two hours! At this point I got a transparent cover (picture 4). and melts the plastic. I cut the panel off the box using a hand modelling saw. The screwdriver is OK. even at the lower speed. After cutting the covering panel. I choose a transparent empty chocolate box. do not throw away this smart. It is very difficult to use electric tools with this plastic. The . I painted the back side with silver acrylic paint. For this delicate drilling. useful material! It is polystyrene (PS). because the blade warms up during sawing and melts the plastic.

perfect without painting. he back side with silver acrilic paint. I made some small cilindric spacers to be separate the speakers from the cover. The cover was mounted with the four outer most screws of the speakers. I made some small cylindrical spacers to be separate the speakers from the cover. The cover was mounted with the four outer most screws of the speakers. Step 12: Enjoy your multimedia station i i .front side keeps the glossy plastic surface. The front side keeps the glossy plastic surface. perfect without painting.

A second jack for battery charging could be included in the right PSP holder. Thanks for your attention and many thanks to Kiteman for correcting English spelling.Et voila! A newly designed multimedia station is ready for use. In this way a unique cord would power both the amplifier and the battery charger. The mounting of the DC jack would be similar to the audio jack and the small power supplier could be hidden inside the case. . It looks great in my living room! A possible improvement would be to allow for charging in the frame.