Printer modifications

Overview
There are several modifications that make the HP Photosmart printer more suitable for our needs. Some changes are required, while most are optional. Some changes are reversible, or only require replacing modular components, while others are irreversible changes. Many are also quite simple to implement. Modifications listed below are optional and reversible, unless otherwise indicated in the title. A general difficulty rating is also included in the title. When a modification is listed more than once, then there are multiple equivalent solutions to achieve the same goal, and probably differ in the tools, techniques, or difficulty required in implementing them.

CD Tray Cutout I (Permanent) (Easy)
Print a PDF with the HP printer itself...

CD Tray Cutout II (Permanent) (Easy)
Trace the plate itself, and try really really hard to make it nice and square...

CD Tray Reflector I (Easy)
Tape in some foil...

CD Tray Reflector II (Difficult)
This is the preferred method. Benefits include higher durability and reliability over the foil method. 1) Acquire a CD/DVD that you're happy to destroy. A white finish has proven to work well; other colors may be acceptable, but have not been tested. 2) Mark the CD using the FTO glass as a template. Make every effort to properly center the glass. 3) Cut a square into the disc. CD/DVD plastic is brittle, and a knife or razor blade will likely crack/shatter the disc. A Dremel tool with a cutting disc is ideal. Cut the hole slightly smaller than the glass plate - you want it to be a tight fit. You can slowly remove excess material with sandpaper or a Dremel tool to achieve the desired fit. 4) Glue the disc to the printer feed tray; be sure to align the disc in the printer feed tray such that the edges of the square cut are parallel to the edges of the tray. Allow glue to cure before proceeding. Using a non-permanent glue (such as silicone gasket sealant) is recommended, so the feed tray can be re-used if the disc needs to be replaced for any reason. 5) Cut a square in the feed tray. The plastic of the feed tray is soft, and should cut easily. 6) Cut a piece of paper slightly larger than the square cutout. Tape it to the bottom of the feed tray with tape. Scotch tape works well, because the paper can be easily replaced as necessary.

Change Printer Cartridges I (Easy)
Use the empty aftermarket cartridges that come with the kit...

Change Printer Cartridges II (Permanent) (Straightforward)
Modify the HP cartridges...

Transfer Cartridge Microchip I (Permanent) (Straightforward)
Use the dental tool to remove the chip and put it on the chipboard... thesharkproject.org/node/650

Transfer Cartridge Microchip II (Permanent) (Straightforward)
Use the dental tool to remove the chip and put it on the aftermarket cartridges...

Transfer Cartridge Microchip III (Permanent) (Straightforward)
If you modified the HP cartridges, then no chip transfer required...

Remove Excess Plastic Covers (Straightforward)
Unscrew plastic parts, pull them off. Rated straightforward rather than easy because you need Torx screwdrivers/wrenches...

Remove Top Cover (Easy)
Work the plastic clips off, and find a new piece of plastic (maybe a Lego part?) to block the optical sensor...

Remove Rollers (Permanent) (Easy)
Eliminate streaking on the printed substrates by removing a set of the plastic rollers from the printer. thesharkproject.org/node/702

This is most easily accomplished by cutting the plastic tabs from the top side, then compressing the spring from the back with a screwdriver, and pulling the spring and plastic roller out.