So, this is my tutorial on fixing a broken power switch on an Nintendo DS Lite.
By fixing, I mean fixing, NOT replacing. So I used a piece of staple and some epoxy glue.
Will it hold ? Well so far it holds.
If you are specifically come across this post, then I'd assume you know how to open an NDS Lite. I assume that because broken power switches are mostly because of a botched installation of the lower casing (yes, I did that).
And you may ask me, why not just replace the entire switch? Well, do it if you can. If you're like me that doesn't have a replacement switch lying around, or maybe you botched it once and not willing to risk it again (yes I botched it twice).
The tools you need :
1. The DS Lite of course, already opened. you can leave the motherboard attached or remove it entirely from the case for better handling
2. A Solder, flux and soldering wire (tin)
3. A piece of staple.
4. Epoxy glue. Alternatively you can use super glue, but I found epoxy glue easier to handle because you have more time for adjustment before the glue sets in.
5. A tweezer for holding small stuff
6. Either a really tiny flat head screwdriver, or a small box cutter, you need it to pry open stuff.
7. A tiny cable, with insides around the same size as the staple, we need the rubber casing/cover. I actually use the cable tie for a headphone I bought.
The steps :
1. Using a solder, heat the two legs/pads securing the metal cover of the switch, you might need to slid the box cutter under the switch so that you can pry it loose. You can do just one side, and very carefully lift it without breaking the other side, or you can just do both sides.
Note : Be very careful not accidentally stripping off the pads on the motherboard. But even if you do, it's not the end of the world, as those pads are only for securing the metal cover onto the switch/motherboard.
2. Now you can remove the plastic cover. that's inside the switch, the broken part. You might want to take note of the placement of the tiny spring, remember it and takes it off.
3. Make a notch in the broken part of the switch. This is for the staple.
4. Cut the staple, take the longer part (we can trim that later). This is our new handle for the switch.
5. Prepare the epoxy glue, If you're using a two part epoxy like me, just mix a small part using a toothpick.
6. Take that piece of staple, put some epoxy glue on it and insert it in the notch we created earlier. Align it so that the thicker part of the staple is put horizontally (so that it doesn't bend when we use the switch).
Make sure it's not too much. We need to insert that piece of plastic back into the switch, If it's too much, the switch might not move.
7. Leave the glue to dry/harden. If you're not too sure, you can leave it longer.
8. If necessary, you can trim the excess glue on glued part so it doesn't impede movement. Use the box cutter.
9. Put it back together. The plastic cover, the spring and then the metal cover.
10. Before you solder the metal cover back, test the switch. If you're careful enough to not use too much glue, it will glide smoothly. If it's stuck, trim the glued part again. You might gonna have to tolerate that it isn't gonna be as smooth as before, just make sure it works.
11. Solder the metal cover back. If you managed to strip off the pads, you might have to glue it (the legs, or the sides, NOT the top).
12. Now you got a working switch. Last thing to do is to make the handle a bit thicker. You can use the cable casing for that. And while you're at it, you might need to trim the handle a little bit shorter.
And that's it. Assemble it back and this time make sure you don't break it again.
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