Filino - appreciate your comments.
Fan I was meaning was a 9cm fan, which is
totally silent - tried it on c. 7.5v, 9v and 12v. I was thinking of relocating the cartridge slot to the rear at the top and the fan immediately under it - there is just enough space - after all, I will be holding the portable when playing it, so no issue having fan at rear of case. It will also help to keep the cartridge slot firmly in place. I tested the fan, yes it works on 4.5 volts but too slowly for much use - give it at least 7.5v and it works well - lots of nice cool air moving quickly, which is what you need. 7.5v is fine, after all, under this and the PSone screen dies. Other fans I have make a noise, this one is totally silent. This fan should keep everything cool - after all, it kept an old PIII I had cool for a number of years.
Tried to remove the N64 screws as some people indicated, gave up so bought a special screwdriver for it - when I have opened the unit up I will experiment - easy to rig some batteries, fan, etc to the two inputs and test, without doing anything further. Best to do this first anyway.

Took pic of the adapter - uses a step-down regulator by the looks of it, and uses capacitors too on the board. Connecting the rightmost pin to + on multimeter and - on the 2nd left pin gives readout - tried it with no load on a 4.5v, 8v and 11.5v battery pack, each time gave 3.4v reading unloaded, put a 3v torch bulb (yes, I know there isn't much draw but I couldn't think of a device I had using 3v presently with lots of drain - don't flame me!!); gave same result on multimeter. I am fully expecting the voltage to drop to a stupid level when given high load, after thinking of your comments further, however the proof will be in the pudding - might be wrong after all and it works fine - only way is to test it after all - either the N64 boots up and stays on for ages fine, or it doesn't - cut and dry.
I figured I would get the N64 working on batteries, and see what I get. If the N64 boots up, I will use a multimeter to see what voltage I get from this step down regulator, then try a game and do the same thing, then let everything run until it dies and see how long it lasts. If the N64 doesn't boot up because the adapter sucks, the adapter will be binned and I will try something else!! It will be interesting, after all the adapter is rated at 1000mA and fused at 1A. Might be I can play games like Mario 64 but not the likes of Donkey Kong.
I may as well try this experiment, I have a stack of powerful photo grade AA's (2700NiMH) and I have this adapter anyway, so only thing I may waste is time (having fun) - that's assuming it doesn't work of course - if it does work, great! Nothing to lose.
I know your comments on sub-C batteries are correct, however the AA's will allow me to test the unit as it stands; if it works (even for over an hour) on such batteries, it would be easy enough to move to sub-C ones to get more playtime (after all, all tests can be done prior to designing a case to put everything into) - however there is no point spending lots of money on these sub-C batteries and finding I can't complete the project (fried boards, etc) - I have no other equipment which uses this size of battery - that would be a waste of money then!! If I get it working (on test) with AA's, it will certainly work better and longer on sub-C batteries, if I use them. Don't be annoyed by people using AA's, there are many advantages to them - sub-C's are better yes, Li-ion are the best, but dangerous potentially so "not for me".
My design for my N64 portable will be a bit different to other ones I have seen on the forum; I will describe more at a future date assuming I can get everything working in principle ok - no point going into concept details too much at this stage. Good chance I may fail in my project at this early stage after all.
What do you mean by "EDIT: Also, 'sony'? My solder sucker..."?