Sorry for the EXTREME lack of update... I've been super busy and havn't had a ton of time to be able to work on monseur Hedge's SNESp.
Anyway, I have a week off now for semester break so I'm gonna get busy on this. I have to commend Hedge for his patience so far.
I tried to find that Bondo marine putty to fill in the edges of my Polycase ZN-40 case, but was unsuccessful in my search. So, after some extensive searching for a replacement, I remembered some stuff that I had used on a previous project a couple years ago. It's called Epoxy Putty. It's really good stuff. It has the 2-part epoxy separated in a tube with the 1st part wrapped around the 2nd part. All you have to do is tear a piece off the stick and then knead it in your hands until you get it a uniform colour. Model it into whatever you're trying to fill and within 5 minutes the stuff is absolutely hard as rock. The only downside is that it takes a bit of work to sand it after due to it's intense hardness. Needless to say, it WON'T come off.
After that was done and I sanded the bulk of it off, I proceded to cut out the holes with my dremel in the front of the case so that I could mold in the controls from a cut up SNES and NES controller (SNES buttons, NES D-Pad).
Here's a picture of that: (The white stuff is the epoxy putty)
And from the back, with the controls super-glued in:
A close up of the D-pad. It's a perfect fit:
And the part of the SNES controller. There was a bit of space between the piece and the case so I filled it in with a little bit of epoxy putty:
After the controls were secured to the case, it was time to do some bondoing. I've gotten fairly confident with my bondoing skills so I'm pretty sure this is going to come out as one solid piece when its done. It doesn't look like much right now because the bondo is kind of sloppy at the moment.
The bondo is drying right now so I'll post up another picture when its done and I finish sanding it. I may need to do a little bit of spot touch ups and then sand it again.