In my long quest of thought of how to make an SD card slot for the ED64 shell without a dremal I concluded the easiest way to do so is to simply not make one. The SD card only just pops out of the case and while there is no way to trim an SD card down to fit in an uncut case a micro SD card would fit easily.

I was wondering if anyone knew anywhere that you can buy a micro SD card adaptor that is smaller than a standard size SD card and consequently will fit in a standard N64 cart shell.