Neo360 - Printable Replacement Shell for Xbox 360

Introducing the Neo360 - a fully 3D-printable replacement shell for the Xbox 360 S, designed specifically for RGH-modded systems without an optical drive.

This is Revision 2 of my original design linked here (originally posted to /r/360hacks back in late 2024 [link]), which I believe was the first ever fully printable Xbox 360 shell. V2 includes significant improvements in airflow, ease of assembly, LED diffusion, and overall usability.

This version also supports an optional 120mm fan mod (printable adapter and mod instructions included).

Full BOM, print settings, and detailed step-by-step build instructions are below.

FEATURES:

• Mechanical momentary push-buttons for Power and Sync (requires soldering to RF board; see BOM)
• Improved structural integrity, less flimsy than V1
• Front USB ports now accessible (unlike V1)
• Improved overall ventilation and airflow design (vs. V1)
• Custom printed LED ring diffuser for improved light dispersion (better than V1)
• Replaces original RF board diffuser ring and capacitive touch button
• Two top shell options:
  • Stock fan version for OEM fan’s ventilation
  • 120mm fan mod version for 120mm PC fan ventilation using included printed adapter, mod instructions included
• Removed body curves for more efficient use of internal space compared to V1
• Rear I/O port alignment and clearance significantly improved from V1
• 2.5” SATA HDD/SSD relocated to optical drive bay area, shortened the HDD/SSD bracket compared to V1
• Keyed power input to prevent incorrect plug orientation (fixed from V1)
• Completely revised mounting system (no more "pole" mounting like in V1), top and bottom shell mounts together directly, independent of motherboard and HDD/SSD bracket mounting directly to bottom shell

IMPORTANT INFO (READ THIS FIRST):

• Designed for Trinity boards (Corona *may* work, but untested)
• XY size is 229.19mm x 241mm - check your printer’s printable area
• Does not support optical drives - this is meant for RGH modded systems where everything you need lives on the HDD/SSD
• 2.5” drive only - no support for 3.5” drive
• WiFi card removed due to clearance issues - ethernet only!
• Soldering needed for front buttons (required) and 120mm fan mod (optional)
• With the optical drive removed, you will probably want to bridge these two pins together on the motherboard’s optical drive socket to make the system think the drive tray is closed, otherwise if the optical drive is not connected, the system thinks the tray is stuck open.

BILL OF MATERIALS:

REQUIRED:

• M3 Heat-Set Threaded Inserts x 9
• 19mm Momentary Push Button x 1
• 12mm Momentary Push Button x 1
• M3 Button-Head Screws x 9 (Six M3x6mm and three M3x8mm)
• 2.5” SATA HDD/SSD Screws x 4

FOR 120mm FAN MOD:

• 120x25mm PC Fan x 1 (any brand, as long as it's 12V or 5V)
• PC fan screws x 4
• You will need to reuse the stock fan’s mounting screws to mount the fan and adapter assembly to the heatsink

OPTIONAL:

• 2-Pin JST-PH 2.0 Plug Connectors x 2 (for front buttons, if you want “quick disconnects”)
• Adhesive rubber pad x 1 (alternative for rubber feet, OR you can use regular adhesive rubber feet)

PDF BUILD MANUAL ATTACHED BELOW