Thanks for the kind words! I really enjoyed making this one, and I can't wait to finish it. To answer a few questions:
I made the case using a project box as a frame. I then superglued/epoxied the hip gear and nes controller to that frame and filled in all the gaps with plastic body filler (bondo). Then I sanded, and filled MANY times. This takes a lot of time and patience, but if you know what you are doing the end result is worth it. I took a lot of pictures of the construction that I plan on posting on my own website (I don't want to load this thread up with pictures).
G-force: The only things I have left is to install are the switches (on/off, cartridge or built-in games), and the 72pin American NES cartridge slot (I REALLY don't look forward to doing this). After that, I just have to touch up the case a little bit and clean up some areas.
The sound works perfectly through the two original hip gear speakers, and I can still use the original volume, color, brightness, and contrast knobs.
Here are a few more pictures.
After painting the case, before mounting internal electronics:
Running a built in game as a dry run to test the controls, sound, etc:
The bottom of the portable, where I plan on installing swtiches, and maybe a headphone jack:
Last picture, a comparison to my other project (MegaJoyBoy):
There is barely enough room on the inside for the cartridge to slide in and out, hopefully I can get this done soon! Thanks again.