I've managed to trim the DC small enough to fit a ZN-45 from poly case. I still need to solder the controller board, and GD-Rom drive, which will be no easy feat as the traces are really close together.
The GD rom board to Motherboard is 50 pins on each, and the things are only a millimeter apart
Controller port isn't a big problem, theres only like 25 points on each board, and the traces are like 1/8 of an inch apart.
I'll get a picoPSU thanks to FamilyGuy's portable thread, as the original PSU is freaking huge. That still leaves about 1.8 inches on each side of the mobo for batteries and controller parts. There's still enough room in the mobo area fo rthe picoPSU to fit.
I'll get pictures tommorow to show you the setup I have currently to make the system so small.
Sadly, I'll be getting rid of the controller ports, so no multi-player(No one plays games with me anyway, I have no freinds
There's going to be a fan at the top, to keep the CPU from building up to much heat in the system, although the PSU seems to cause %60 of the systems heat, so It shouldn't get hot enough it will fry the system.
And yes, I did take the screen into acount. I'm going to take the PS1 screens case and bondo it to the front so the screens mobo doesn't take up room in the case.
I know, pics or it didn't happen