TiVo Community Forums Archives - Network Jack Cutout Instructions for TivoNet or TurboNet (Keystone Jack and TiVo)

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Network Jack Cutout Instructions for TivoNet or TurboNet (Keystone Jack and TiVo)
(Click here to view the original thread with full colors/images)

Posted by: JakFrost

Geoffrey Reynolds (gsr) has asked me a question through e-mail regarding how exactly did I cut the hole in the back of the DirecTiVo unit to fit the Keystone network jack above the phone jack. Instead of replying through e-mail only to him, I thought I'd post the reply in this thread in case there are more people interested in doing the same thing.

I actually got this good idea from a previous thread on this message board that I read months and months ago but now I can't find. However, the good thing is that now there seem to be many more threads on the message board about putting in Keystone jacks into your DirecTiVo or Stand-Alone TiVo until when you connect the TurboNet and TiVoNet cards and CAT5 network cables.

This is of course for people that actually care about such things as looks for their TiVo's. Since a much easier way to get the network cable out of the TiVo is just to snake it through the holes underneath the TiVo that are used for ventilation.

TiVo Keystone Jack Posts

Here are two good posts that I found on this topic that should be used as a reference.

Who's got the Best Practice - Tivonet.
For those of you who like things to be pretty...

TiVos with Installed Keystone Jack Pictures

Here are some pictures of TiVo's with the Keystone jack mods.

Sony DirecTiVo SAT-T60 by JakFrost
Philips DirecTiVo DSR6000 by psperry
Sony TiVo by RobD

Parts

Additionally, here are links to the parts that you'll need to complete this job.

http://www.cyberguys.com/IMAGES/p3434A.JPG
Nibbler - Sheet Steel Cutter Tool from CyberGuys

http://www.9thtee.com/images/KSSRJ45.jpg
RJ45 Keystone Jack Insert from 9th Tee

http://www.9thtee.com/images/images2/110Economy.jpg
110 Block Economy Punch Down Tool from 9th Tee

You can also pick up the Nibbler tool at your local RadioShack, hardware store, or online computer retailer that specializes in customized computer cases. This is a fairly popular tool for cutting sheet metal and it is recommended for this job, because unlike the Dremel Rotary Tool it does not spray dangerous metal shavings into your TiVo.

The same goes for the Keystone jack and the 110 punch down tool. You can find these pretty much anywhere that sells network cables or home audio jacks. Just be careful of the prices that you pay, some places charges you more than $10 for a single jack.

Optional Tools

Dremel Rotary Tools

Dremel Rotary High-Speed Metal Cutter Bits

Optionally, you can use the Dremel Rotary Tool, cordless or corded, to cut the metal for the hole for the Keystone jack.

Please be aware thought that this is NOT the recommended way to do this job, the Nibbler is the better tool for this job. The Dremel will spray dangerous metal shavings into your TiVo unit and these shavings have the potential to short out the chips on the unit if they cause a short-circuit on the exposed chip legs.

Also, don't be a JackAss(TM) and always wear eye protection when using the Dremel tool. Be aware that only YOU are responsible for YOUR actions but OTHERS will have to live with the consequences. Don't be stupid and have your kids and friends call you Papa Pirate or Mama Pirate for the rest of your life. After all, why ruin your eyesight during a mod that was supposed to improve your TV watching experience. Wear Eye Protection.

Coincidentally, I actually used the Dremel tool with a high-speed metal cutter bit #115 to cut the metal for my Keystone jack but it was a lot of work and hassle. If I had to do it again, I would not do it this way but buy and use the Nibbler tool instead.

Also of notice, before I started cutting the metal in my job I made little cardboard box that I placed inside the TiVo and taped it to the inside wall to collect the metal shavings. Even though the little collection box was secure and well taped I had a problem with some of the little metal shavings getting out. Just to be sure, I had to use a vacuum cleaner and an air spray can to clean out my unit. I will once again recommend that you use a Nibbler tool for this job.

Drill

While not listed or linked above, you will need a drill for this job to create the initial hole for the cutting for the Nibbler tool and even to get the Dremel tool to get started. Any drill will do as long as you use a drill that is a little larger than the size of the little head on the Nibbler, so that you can place it inside the drill hole to get started.

Additionally, when you are going to be doing the initial drilling to make the hole for the Nibbler to come through you should tape a little block of foam or sponge to the inside of your unit so that the metal shaving from the drill bit will be collected in the foam or sponge and not spread to the inside of your unit. Thanks to StanSimmons for this idea in his post.

Instructions

I written some short instructions on how to perform this modification to your TiVo. This instructions are only for cutting the hole and placing the jack into the TiVo. The actual punching down of the network connection into the jack and the running of the network cable on the inside of the TiVo is left up to the user. The punch down of the jack is not really a problem, as long as you use a 110 block punch down tool (the one linked to in this post) and follow the color coded sticker on jack and the wires coming out of the network cable.

Step 1

code:
 ____________
|  TEL LINE  |
|------------|
|            |
|            |
|            |
|            |
|            |
|            |
|            |
|            |
|   ______   |
|  |_]  [_|  |
|  |      |  |
|  |______|  |
|  |______|  |
|____________|

Locate an empty space for the Keystone jack. (In DirecTiVo's the best place is right above the phone jack.)

Step 2

code:
 ____________
|  TEL LINE  |
|------------|
|            |
|  ________  |
| |        | |
| |        | |
| |        | |
| |        | |
| |________| |
|            |
|   ______   |
|  |_]  [_|  |
|  |      |  |
|  |______|  |
|  |______|  |
|____________|

Prep the location of the new jack.
Take the Keystone jack and place the front of it against the spot where it will be mounted.
While holding the Keystone jack, take a pencil and draw an outline of it to serve as a guide.
First do the outline of the top, left, and right.
For the outline on the bottom you will have to move the Keystone jack down by about 3mm or 1/16 of an inch since the Keystone jack has a flexible lip underneath that will need space to pass though the opening and latch onto the case.
Optionally, if you wish you can use a scalpel, an Xacto Knife, or just a knife and cut an outline of it against the sticker to make the outline more noticeable and to make clear and clean cuts on the sticker. (You should leave square sticker still stuck onto the case since it is quite difficult and unnecessary to remove it.)

If you are going to be cutting make sure to aim the knife and make the cuts away from your body and fingers, not towards.

Step 3

code:
 ____________
|  TEL LINE  |
|------------|
|            |
|  ________  |
| |O       | |
| |        | |
| |        | |
| |        | |
| |________| |
|            |
|   ______   |
|  |_]  [_|  |
|  |      |  |
|  |______|  |
|  |______|  |
|____________|

Tape a piece of foam or sponge on the inside of your TiVo unit opposite of the place where you will be drilling the starting hole. This foam or sponge will be used to catch the metal filing from the drilling from getting into the components of the TiVo. Thanks to StanSimmons for this idea in his post.
Turn your TiVo upside down so that the foam or sponge captures the metal filings and later so that they fall down and out when you remove the foam or sponge.
Once the area has been prepped you can now attempt to drill a starting hole in the top-left corner, inside the outline.

Careful with the drill it is very sharp. Wear eye protection. Don't push too hard against the metal with the drill, let it do its work. Don't touch the drill bit after it has been used, it is hot. Don't place the drill bit down on your table or workbench since it will burn a little hole it in.

Step 4

code:
 ____________
|  TEL LINE  |
|------------|
|            |
|  ________  |
| |O>>>>>>>| |
| |^     \/| |
| |^     \/| |
| |^     \/| |
| |<<<<<<<<| |
|            |
|   ______   |
|  |_]  [_|  |
|  |      |  |
|  |______|  |
|  |______|  |
|____________|

Remove the foam or sponge used for catching the metal drillings, being careful not to spill any into the TiVo.
Now you should use the Nibbler tool or Dremel tool to cut the sheet steel away. (Be sure to follow the outline. You should also cut 1mm or 1/32nd of an inch outside of the outline to allow free room for the jack to enter.)

Step 4

code:
 ____________
|  TEL LINE  |
|------------|
|            |
|            |
| |XXXXXXXX| |
| |XXXXXXXX| |
| |XXXXXXXX| |
| |XXXXXXXX| |
| |XXXXXXXX| |
|            |
|   ______   |
|  |_]  [_|  |
|  |      |  |
|  |______|  |
|  |______|  |
|____________|

Clean the cut out area and check the fit of the Keystone jack.
Where necessary trim a little metal away with a metal file to make the Keystone jack fit.

Step 5

code:
 ____________
|  TEL LINE  |
|------------|
|            |
|  /======\  |
| |_]    [_| |
| |        | |
| |________| |
| |________| |
|  \======/  |
|            |
|   ______   |
|  |_]  [_|  |
|  |      |  |
|  |______|  |
|  |______|  |
|____________|

Place the Keystone jack straight into the opening so that the little lip is on top and the latch with the lip is on the bottom. (So that the jack faces in the same direction as the phone jack, with the little lever that clicks into place is facing up.)
Once it is in 5mm, tilt the jack downwards to allow the top lip of the jack to pass through the opening and catch on the other side. The jack should be partially in the hole, with the top lip on the outside of the hole and the bottom lip and latch still on the inside.
Now straighten out the jack. You will need to use a small flathead screwdriver to flex the bottom lip and latch to make it pass through the bottom and catch on the outside of the hole. The jack should be in firmly but softly enough that you could flex the bottom piece and remove the jack if necessary in the future.
That's it, you're done.