iPod Classic MKII Assembly Guide | Boxy Pixel

Before tightening any fastener, make sure all parts are fully seated and held firmly together. Do not use the fasteners to pull parts into alignment. If a fastener does not turn smoothly, stop and realign the parts before continuing. Do not force it.

Important for Brass Builds: Brass is electrically conductive. Areas where brass components may contact the iPod logic board, connectors, flex cables, test points, or other electronic components must be insulated before assembly. Apply conformal coating, Kapton tape, or another suitable nonconductive barrier to the areas identified below.

Allow conformal coating to dry completely before continuing. Brass is supplied unfinished. If you would like to preserve its polished appearance, this is also the best time to apply ProtectaClear or another suitable non-yellowing brass clear coat to the exterior cosmetic surfaces.

Test During Assembly: Test the MKII board before beginning and again at the testing points identified throughout this guide. Testing in stages makes it easier to identify a loose cable, incorrect connection, or component issue before the housing is fully assembled.

1.0 Before You Begin

This is an advanced installation. Carefully review the entire guide before beginning. Work slowly, keep the battery disconnected whenever possible, and verify the orientation of every flex cable and connector before applying power.

If you plan to install additional upgrades, such as an iFlash adapter, Rockbox, a Taptic Engine, or other modifications, complete and test those separately whenever possible.

Avoid installing every modification at the same time. Installing too many upgrades at once can make troubleshooting much more difficult if the iPod does not work as expected.

1.1 Materials Needed

• Compatible iPod Classic donor unit
• Screen
• Hard drive or compatible iFlash storage adapter
• Boxy Pixel MKII housing kit
• Boxy Pixel MKII electronics and flex cables
• Appropriate battery for your selected housing
• Kapton tape or conformal coating for brass builds
• External antenna, optional
• Electronics-safe adhesive or another suitable strain-relief material, optional

1.2 MIN Housing Compatibility

The MIN housing requires a compact microSD-based storage adapter. The iFlash Solo uses a full-size SD card and will not fit inside the MIN housing.

The MIN housing also requires a specific battery size. Review the battery and storage requirements before beginning:

MKII MIN Battery and Storage Compatibility

2.0 Insulate Brass Components

This section is required for builds that use a brass front housing, rear housing, or brass internal components.

The blue highlighted areas in the following images show locations where brass parts may come close to or contact the iPod logic board. At a minimum, apply conformal coating, Kapton tape, or another suitable nonconductive barrier to these locations.

You may also apply insulation around the iPod 30-pin connector and the Boxy Pixel USB-C connector if either area may contact the brass housing.

Inspect your individual build carefully. Component position and tolerances can vary, so insulate any additional location where a brass part could contact an exposed electrical connection.

Add a small piece of Kapton tape over the two gold test points on the back of the power flex cable, as shown in blue below. These test points may be used to measure PCB voltage during troubleshooting, but they should remain insulated during normal assembly.

3.0 Disassemble and Prepare the Donor iPod

Carefully disassemble the stock iPod and prepare the internal components for transfer into the Boxy Pixel housing.

Keep track of the original components and inspect the donor logic board, screen, click wheel, storage device, flex cables, and connectors before continuing. Whenever possible, confirm that the donor iPod operates correctly before installing the MKII components.

4.0 Test the MKII Board

Before connecting the MKII board to the iPod, perform an initial power test.

Connect a USB-C power cable to the MKII board as shown below. The indicator LEDs should illuminate.

Turn on Bluetooth power using the top switch shown below. A red LED should begin blinking on the blue Bluetooth module. This indicates that the Bluetooth module is receiving power and searching for a connection.

After completing this test, turn off Bluetooth power and disconnect the USB-C cable before continuing.

5.0 Connect the MKII Flex Cables

Flex Cable Orientation Warning: The power and audio flex cables must be inserted in the correct orientation. Carefully compare each connection to the photos before closing a connector lock. An incorrectly inserted cable may prevent operation or damage the connected components.

5.1 Identify the Power Flex Cable Ends

The end labeled “iPod” connects to the Boxy Pixel MKII board. The opposite end, marked only with a “+” symbol, connects to the iPod logic board.

5.2 Connect the Power Flex Cable to the iPod

Insert the “+” end of the white power flex cable into the iPod logic board connector with the marking oriented exactly as shown below.

Make sure the cable is fully seated, then press the brown locking tab down to secure it in the same manner as the original iPod flex cable.

5.3 Connect the Audio Flex Cable to the iPod

The white audio flex cable has a slight “J” shape.

Locate the 13-pin audio connector on the iPod logic board. In the example below, the connector is labeled A1F. Gently lift and rotate the brown connector lock.

Slide the audio flex cable fully into the connector, then rotate the brown locking tab back down to secure it.

5.4 Connect the Power Flex Cable to the MKII Board

Rotate the black power-flex connector lock upward into the vertical position, as shown below.

Slide the power flex cable into the connector with the gold contacts facing down. Rotate the black locking tab down to secure the cable.

When installed correctly, the brown side of the cable and the “iPod” text should remain visible, as shown below.

5.5 Connect the Audio Flex Cable to the MKII Board

The white “J”-shaped audio flex cable connects to the J1 connector on the MKII board. Lift the brown J1 connector lock as shown below.

Insert the audio flex cable fully, then rotate the brown connector lock down to secure it.

6.0 Connect the Battery

The MKII board supports two battery connection types. Choose the instructions that match your battery.

Do not connect two batteries at the same time.

6.1 Conventional iPod Battery

If you are using a conventional iPod battery with an orange flex cable, insert the battery flex cable with the gold contacts facing up, exactly as shown below.

Battery Orientation Warning: Incorrect battery-flex orientation may cause the battery, cable, connector, or PCB to become hot and may permanently damage the components. Disconnect the battery immediately if any component becomes unusually warm.

The following image shows the conventional battery flex cable fully inserted.

6.2 Boxy Pixel 1250 mAh Battery

Follow this section only if you are using the Boxy Pixel 1250 mAh battery.

Align the custom battery connector over the matching PCB connector, as shown below.

Press the connector straight down until it is fully seated. It should connect without excessive force. If it does not fit easily, stop and verify the connector orientation.

When using the Boxy Pixel battery, make sure the unused BAT IN connector lock is closed so it does not interfere with rear-housing assembly.

The following photo shows the BAT IN connector in the incorrect, unlocked position. Do not leave it this way.

7.0 Perform the Initial System Test

Before installing the components into the housing, test the assembled electronics.

Turn the unit over and move the BT PWR switch to the left, as shown below. Keep the other top switch in the position shown.

A red LED should flash on the Bluetooth module. This indicates that the module is powered and searching for a connection. A blue LED may also illuminate and can be ignored during this test.

When a USB-C charging cable is connected, the red D4 LED on the MKII board should illuminate steadily to indicate charging power.

When the battery is fully charged, or when no battery is connected, the green D7 LED should illuminate.

Try powering on the iPod. The screen and click wheel must be connected for this test.

After confirming correct operation, turn off the unit and disconnect the battery before continuing with housing assembly.

8.0 Install the iPod Assembly into the Front Housing

Before installing the iPod logic board into the front housing, disconnect the battery and disconnect the two white flex cables from the MKII board.

8.1 Install the Center Button

Insert the center button into the click wheel as shown below.

The example uses a 5th-generation iPod Classic logic board, click wheel, and center button. The 6th- and 7th-generation assemblies follow the same basic process, although the parts look slightly different.

Center Button Fit Note: Center-button height may vary slightly between donor iPods. The iPod logic-board dome switch includes a small rubber contact, and the Boxy Pixel design allows a slight amount of clearance for adjustment.

If the center button feels looser than desired after testing, add a small amount of Kapton tape or thin spacer material. Begin with the thinnest possible material and test the button again before adding more.

8.2 Position the Click Wheel and Logic Board

Align the four click-wheel ears with the front-housing cutouts indicated by the yellow arrows below.

Hold the click wheel in position while carefully folding the logic board, screen, and iFlash adapter or hard drive into the front housing.

Keep light pressure on the logic board during installation. The click wheel may move out of position if the logic board is not held down.

8.3 Install the Metal Retainer

Slide the new metal retainer into position as shown below.

While holding the retainer in place, turn the assembly over and verify that the click wheel has not moved.

Install the six retainer fasteners using light pressure. Start each fastener carefully and confirm that it turns smoothly before tightening it.

After the retainer is installed, test the center button and verify that the click wheel moves and clicks correctly before continuing.

9.0 Install the MKII Board and Top Switches

Mount the MKII board and the two metal top switches before reconnecting the power cable, audio cable, and battery.

9.1 Install the LCD Foam

Cut and install a small piece of foam behind the upper portion of the LCD.

The foam should apply light pressure to the top switches, help reduce movement or noise, and help keep the LCD in position. Do not use excessive foam thickness or compress the LCD forcefully.

9.2 Position the Metal Top Switches

The two metal top switches have a specific orientation. The two small legs should slide under the edge of the MKII board and point toward the foam, as shown below.

Brass Switch Compatibility Note: Using brass top switches together with a brass front or rear housing may cause the hold switch to operate incorrectly or may produce unwanted electrical clicking or noise. For brass-housing builds, anodized aluminum top switches are recommended. Brass switches may be used with anodized aluminum housings.

Align the metal switches with the small black plastic switch actuators on the MKII board.

At the same time, confirm that the MKII mounting hole aligns with the threaded hole below it.

Do not install the fastener until the holes are properly aligned. The threads are very small, so use light pressure and do not force the fastener.

Once the MKII board is aligned and both switches move correctly, carefully install the mounting fastener.

9.3 Reconnect and Retest

Reconnect the power flex cable, audio flex cable, and battery connector.

Test the iPod again before continuing. Hard drives, iFlash adapters, connectors, and flex cables can shift slightly during assembly.

After successful testing, add strain relief to the two white flex cables. Kapton tape may be used to keep the cables from moving or pulling on the connectors.

Do not sharply crease the flex cables or place tape over connector locks in a way that prevents future service.

10.0 Position the Battery and Storage

Position the battery and iFlash adapter or hard drive before installing the rear housing. Confirm that no cable is pinched, sharply folded, or resting against a sharp edge.

10.1 MIN Housing iFlash Position

When using a MIN rear housing, trimming the iFlash adapter along the dotted line marked on the iFlash board is recommended.

The adapter may fit without trimming, but it can shift upward toward the MKII board and make rear-housing installation more difficult.

The following image shows the iFlash adapter being moved downward toward the 30-pin connector while the internal components are still accessible.

11.0 Install the Rear Button and Rear Housing

11.1 Position the Rear Bluetooth Button

Place the rear Bluetooth button into the rear housing from the inside.

If needed, use removable tape on the exterior of the housing and button to hold the button temporarily during assembly, as indicated by the red outline below.

Install the rear housing over the two top switches while keeping the rear button in position.

11.2 Adjust Rear Button Movement if Necessary

If the rear Bluetooth button does not move or actuate the PCB switch, first confirm that the button, rear housing, and MKII board are fully seated and correctly aligned.

If additional spacing is still required, add a small removable shim to the recessed area shown in blue below. Begin with the thinnest possible material and test the button before adding more.

A thin piece of Kapton tape, card stock, or another stable spacer material is recommended for initial adjustment. Avoid applying permanent adhesive until the required thickness has been confirmed.

11.3 Install the Rear-Housing Fasteners

Make sure the front and rear housings are fully seated and aligned before installing the four hex-head fasteners.

Do not use the fasteners to pull the housings together. Start each fastener gently and stop if you feel unusual resistance.

11.4 Add Headphone-Jack Strain Relief

To reduce movement and improve the long-term durability of the headphone jack, add a small amount of suitable electronics-safe adhesive between the headphone-jack body and the PCB in the highlighted area below.

Do not allow adhesive to enter the headphone-jack opening, electrical contacts, connectors, or nearby switches.

12.0 Complete Final Testing

Test the completed unit thoroughly before installing either glass panel.

At a minimum, verify the following:

• The iPod powers on and boots normally.
• The screen displays correctly.
• The click wheel and center button operate correctly.
• The hold switch operates correctly.
• The Bluetooth power switch and rear Bluetooth button operate correctly.
• The Bluetooth module powers on and pairs as expected.
• Headphone audio operates correctly.
• USB-C charging operates correctly.
• The battery does not become unusually warm.
• No component, flex cable, battery, or storage device shifts when the housing is handled.

Testing before installing the glass allows the unit to be reopened more easily if an adjustment is required.

13.0 Install the Rear Glass

When you are satisfied with the final testing, remove the clear protective film from both sides of the rear glass.

Remove the adhesive backing from the inside surface of the glass. Avoid touching the inside cosmetic surface.

Carefully align the glass with the rear housing, then press and hold around the edges to activate the adhesive.

14.0 Install the Front Glass

Remove the clear protective film from both sides of the front glass before installation.

Do not leave the film installed while positioning the glass. The film can make alignment more difficult and may become trapped against the adhesive.

Remove the adhesive cutouts carefully. Avoid touching the inside surface of the glass, as fingerprints or dust will be visible after installation.

Remove the adhesive liner. If available, use a clean air puffer to remove dust from the screen and inside lens area immediately before installation.

Carefully position the glass in the front housing using light pressure. Once aligned, press and hold around the edges to secure the adhesive.

15.0 Charging LEDs and Battery Indicator

The top of the unit includes small openings for the MKII charging-status LEDs.

• Solid red LED: A USB-C charging cable is connected and charging power is present.
• Green LED: The battery is fully charged, or no battery is connected.

The battery indicator displayed on the iPod screen may not accurately represent the battery’s actual charge level after installing a replacement or higher-capacity battery.

16.0 Troubleshooting and Optional Upgrades

Use the following guides for additional installation, setup, and troubleshooting information:

• Taptic Engine Installation
• External Antenna Installation
• iPod and MKII Troubleshooting — work in progress
• Bluetooth Pairing
• Bluetooth Device Compatibility — work in progress
• Battery Calibration
• Adding USB Data Transfer to the MKII Board

Support Scope: Boxy Pixel specializes in precision housings, mechanical components, and Boxy Pixel electronics. Donor-iPod faults, iFlash configuration, storage formatting, iPod software modifications, Rockbox installation, and third-party components may require additional research or assistance from their respective manufacturers or user communities.