) In my (almost) a year of building portables and being on these forums, I have not once used bondo. Hard to believe, no? 
Well think again!Here's what I started out with after cutting, a nice square piece of plastic (identical back not shown for obvious reasons):
Then after a few hours of cutting, hot gluing, epoxy-ing and finally laying down some unsanded bondo, I got this!
After sanding out the bumps, adding a bit more bondo here and there, and laying down 2 or 3 coats of primer, things were starting to take shape.
And while that's all fine and dandy, every good portable needs a back plate, no? So here's what mine looked like after cutting and primering:
Wondering what those notches on the sides for the back plate were? Only one way to answer that question....
MOCK UP TIME!!!
Battery holders! XD
And everything in place:
In the end, it'll be about 2 inches thick and be a nice satin black, brought to you by Krylon Fusion! It sports a 2.5 inch Intec LCD (Thanks, Marshall!) and a rather odd motherboard variation of the Super Joy III that I'd never seen before. Still, it was fun deciphering the leads!
The dials you see in the front there are screen power, brightness, volume, color, and the headphone jack. The speaker'll be on the top side plate. Seeing as my friend actually owns more pirate/famicom carts than NES ones after living 3 years in downtown Shanghai, I'm keeping the 60 pin slot there and grabbing him a converter to play his NES collection. It'll also have a player 2 jack on the top, but again, he owns more pirate pads than real ones, so it'll be the 9-pin Genesis style input instead of the run-of-the-mill NES controller input. Look for more updates coming soon!Thanks,
CTFan
I painted the case, bent the kickass brass siding, wired her up, and nothing. It seems the screen I got from marshall was already shot beforehand. 
So I threw it back in the antistatic box, and maybe it'll work better later. Oh well. I guess it'll have to be his birthday present now instead!
