Here is a status update for the NES Top Loader portable!
Assembling the front half of the case. Using size M2 sheet metal screws to attach the PCBs to the case. Holes are tapped with a 1.5mm drill bit before hand. For those that know the PSone screen accepts 7.4V then converts it down to 5V in some areas with a 7805 linear regulator. I removed the 7805s and attached my 5V switching power supply to the pads which dropped the power draw of the screen.
The back side houses much more parts. Batteries, switching powersupply, NES Top Loader PCB, speaker, amplifier, and volume control are all housed here. There is no hotglue in this portable. Everything is mechanically held in place. Some electrical tape is used to insulate parts but that is about it.
The button on the right is supposed to be for an internal MCU (like a MSP430) if I ever want to add more functionality to the portable.
I have some extra space between the front pcb boards and the rear pcb boards inside the case. I will be able to slim off about 1/8″ – 3/16″ off the thickness on the next case.
Like all portrait layout portables the top is a bit top heavy but it still has a good balance because of the thickness of the portable. The controls are laid out in the exact same dimensions as a real NES controller so it feels really nice. It has enough battery power to go for about 10 hours at max volume. I will need to tweak the audio amp a bit however as the volume is a bit soft. Should be able to adjust it by changing two resistors on the SparkFun amplifier board.
Check out the NES Top Loader project page for more details.