Ended up making 2/3 of a system from scratch, however; the list of improvements were: * replaced the old screen with a better one. Also gives better battery life! * used NES dpad and board so works like a NES controller now * no ridges over the button areas now * shoulder buttons work evenly * larger speaker for better audio * fan in center of system so virtually silent now * provided a relocated memory cart port as his memory card failed. Easy to open system and put card in as a result. Took quite a bit of work. Internals pics: Backing Front (note the relocated memory card port - there is plenty of space there for a card to be slotted into) ...and i've put a diagram on there to show which way up to put the card. System is easy to open up, only held together by two strips of duct tape. Fast to open. Video: http://www.youtube.com/watch?feature=player_profilepage&v=QHrvsH4lGYk
As always, very cool! I am feeling inclined to make a n64 portable after I finish my snes portable project.