How to modify Starlink Mini to run without the built-in WiFi router

Summary

The Starlink Mini terminal is designed as a compact, all-in-one solution with an integrated Wi-Fi router. While this design is ideal for typical consumer use, certain applications—such as custom networking setups, embedded installations, or power-constrained environments—may benefit from removing the internal router entirely. In this article, I’ll detail the process of physically removing the built-in Wi-Fi router board from the Starlink Mini, allowing the terminal to operate solely via Ethernet and offering greater flexibility for advanced users. Please note that this modification applies only to the Starlink Mini 1 (as of June 14, 2025). Hardware changes in future models, such as the expected Mini 2, may render this process invalid. Starlink Mini teardown The disassembly process requires patience and accuracy. I recommend using metal spudgers and a plastic prying tool. Additionally, you will need a thin, flexible knife or a thin metal wire to remove the router’s PCB. I prepared a video manual about the teardown process. Please note that there is no need to remove the metal plate from the Starlink PCB. You can stop the teardown process after removing the router’s PCB. VIDEO Removing the metal plate is strongly discouraged. This plate serves as both a heatsink and an EMI shield. The Starlink CPU runs hot, and without proper cooling, it may throttle the CPU or antenna array. In addition, the plate is glued around the corners with conductive adhesive to ensure effective electromagnetic shielding. The Starlink Mini PCB generates significant EMI, and SpaceX reportedly faced challenges achieving compliance. Removing the plate can lead to increased emissions and potential interference with nearby electronics. Starlink Mini PCB connector The exact type of the connector is unknown. It might be a custom order. But the pitch of the connector is 2 mm, so any standard 2 mm header will fit here nicely. You may notice that this connector is secured with a similar conductive adhes...