open up the Mac mini, you first discharge static electricity. This is the same phenomenon that causes the little zap you experience as you walk across a carpet and touch a metal lamp. This zap can damage the electronics inside the Mac mini. To prevent this damage, neutralize your body's static charge. Then wield your modified putty knife and dig in.
Modding a putty knife
Modifying the putty knife is important to opening the Mac mini. You'll have a harder time if you don't, and you risk damaging the mini's case. The idea of this mod is to create a bevel on the short edge of the putty knife blade. You bevel only one side of the blade. This one-sided bevel enables the knife to slip into a narrow crack in the Mac mini's outer cover.
If a someone points out that a cutting knife is already tapered and might be a better option, don't let that person near your mini. A knife's point and sharp edge will take a toll on the Mac mini's case. The putty knife is a better choice, and beveling one side of the edge is quick and easy:
1. Place a sheet of 120 or 150 grit sandpaper flat on a table or workbench.
2. Holding the short edge of a putty knife at a 45 degree angle with the blade down, move it up and down the sandpaper for two or three minutes.
3. Check the edge periodically to see if your bevel is coming out even.
Bevel only one side of the putty knife edge. You need the other side to remain straight in order for the putty knife to be effective.
Discharging static electricity
Here's how to safely discharge static electricity from your body:
1. Turn off the Mac mini and unplug all cables except the power cable.
Keep the power cable plugged into the wall to draw away any static electricity.
2. Touch the metal part of the Mac mini.
This discharges the static electricity you may be carrying.
After you discharge, try to remain seated until after you finish closing up the Mac mini. If you get up to walk around, you can build up another static charge and you'll need to discharge yourself again. Repeat Steps 1 and 2 before touching any parts inside the Mac mini.
3. Unplug the power cord.
Popping the top
After you've discharged static electricity, you're ready to open up this puppy. This is a tricky maneuver the first time you do it. The basic procedure is to use the modified putty knife to widen the gap between the outer casing and the inner plastic housing. This gap isn't apparent. It looks more like a thin line than a gap, but the bevel in the putty knife forces the gap open. You then use the putty knife to release the tabs.
Here's how to open the mini:
1. Place the Mac mini upside-down on a soft cloth with the rear port panel facing you.
2. Place the edge of the modified putty knife on the place where the aluminum outer casing meets the inner plastic housing.
Make sure the straight side of the putty knife faces the outer aluminum case and the beveled side faces the interior plastic of the Mac mini.
3. Press the putty knife straight down into the narrow space between the outer aluminum casing and the inner plastic housing.
You may find it easier to start with a corner of the putty knife. You need to use some force when you press down. Don't be timid about it.
To avoid scratching the aluminum case or gouging the plastic, press the putty knife down vertically, and not at an angle. Also, take care not to slip with the putty knife.
4. Stop pushing when the putty knife suddenly slips down about a half inch or when you feel it stop.
5. Push the handle of the putty knife outward and down, to release the tabs inside.
Don't use a lot of force here.
Clicking sounds indicate that the tabs are releasing. Keep pushing with the putty knife until the base of the Mac mini rises slightly above the outer case.
6. Repeat Steps 1 through 5 on the opposite side to lift that side.
You may find that the first side of the mini has slipped down again. This means that you didn't lift the side far enough and the tabs have reengaged. If this is the case, go back and repeat the procedure.
Most of the tabs on the sides are now disengaged and the port panel is lifted up slightly.
7. To release the remaining side tabs and the three tabs on the far side, lift the rear port panel and tilt the housing back.
You hear more clicking sounds as you do this.
8. Continue pushing the port panel up and back until the Mac mini clears the outer casing.
9. Remove the body of the Mac mini from the outer casing and set it on its rubber bottom.
You're now ready to start disassembling the guts of the Mac mini.
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