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could i split the wires coming out of the class d amp so it has a audio jack and a power on/off for the speakers? so that way i can still sit in the living room without being told to turn it off and not annoy anyone? also can i put the roms on the sd before puting the sd in? so i dont need to deal with the wifi dongle junk? the pocket pigrrl can be found here: http://www.thingiverse.com/thing:807591
You would have to reduce the amp gain for an audio out/earbuds jack; 2.5W would be too much for your ears unprotected; I second the recommendation for a volume control (either software or hardware).
One hardware solution would be to desolder the trimpot on the little class-D amplifier and wire in something attached to the shell.
I have also seen mention of using a rotary encoder connected to the pi itself to control the volume, but some dreaded programming would be involved.
Actually, I was looking for 10k potentiometers and saw that somebody makes snap-in thumbwheens for pots similar to the one on Adafruit's little class-D amplifier. I didn't see anything for that specific pot, but you have a 3D printer, right?
Thumbwheel similar to what you would need.
Think it would be better if you added a volume control. So you could always turn it down if it's to loud. No need for additional switches.