Once again I've been playing with Adobe Illustrator (
I don't have a spare ribbon cable to extend to the laser assembly if I mount it on the back, so why not have the screen mounted externally and flip up like in some other PSOne portables? That shape would be way easy to do once I get my vacuum forming table up and running (over spring break). The CD would spin on the inside of the case, and I could make up something to protect it from wires and other stuff once I get to that point.
Only possible drawback is if there isn't enough thickness to the case for the laser assembly to sit inside it. According to the Polycase.com website, the ZN-40 case is 1.675" thick. Think that's enough?
Anyway, here are some pictures:
Basic outline
Proof that the SNES mini will fit (I'm making an SNESp with the ZN-40 before this PSOne idea)
All the guts crammed in (I know I still have the SNES mini board in there - I'm using it as a placeholder until I get a good scan of my PSOne board. It's only a little bit wider and longer than the SNES)
So, overall it's going to be cramped as all get-out but I think it might work.
Edit: Holy cow you know what I just realized? After I get the edges all bondo-ed out on the front for my SNESp, I could just make a mold of that and vacuum form another case for the PSOne portable! Why go to the extra effort of bondo-ing another case if I'm using something that's the same external shape?

