Looks strangely familiar, yes? It uses the same outline as Ben's NES portable (which I used for my Stupendo - finished pics forthcoming, I promise!) However, the controls are moved down by about half an inch from where I have them in the Stupendo. This gives me space to put the speakers up above the controls (as opposed to below them) so I can cram more in the way of power, video, and player 2 jacks at the bottom. It also helps with balancing the unit while holding it (the Stupendo's fairly comfortable, but moving the buttons down would really help with weight distribution). Since I'm going to be vac-forming, I think a raised section for the controls would allow me to get around the problem of fighting for space with the edges of the PSOne screen board (which was problematic with my start and select buttons on the Stupendo). I'll admit that that idea was partly inspired by the snes2go, except in that design both the screen and controls were raised. I wouldn't have to raise them too much, either. I think it would only have to be around 1/4" or under to get the controller boards up and out of the way, right?
Still deciding whether or not to relocate the cartridge slot - that would be a lot of work if I'm making multiple units. However, it would look hella cool and wouldn't add too much to the thickness of the unit. Since I plan on only using Sony Infolithium L's from now on, the battery would just sit below the cartridge connector if I do rewire it. Also, the shoulder buttons will be on the back instead of the shoulders like on the Stupendo. I'll be doing this for two reasons: 1) balance and 2) I've scooted the buttons down too far in this design to even reach the shoulders with my index fingers. Now that I've had some personal experience with a finished portable, I fully understand why so many people put their shoulder buttons on the back.
So, what do you think? Good, bad... ugly? I know it looks kinda bland right now, but once it's done and colored it will be cool. It's a simple plan from a simple man, and sometimes that's what works best.
You should definitely post pics of your Nintendo Stupendo (<---I like the name btw) I would just work on one first, and then decide if you wanted to make a bunch. You might completely change your mind about mass production. 