Coming on nicely. To get the two pieces to lay flat you need to use a sheet of fine/medium sandpaper and using even pressure, gently rub the case over the sandpaper to get a even and flat surface. I put on the paper (in pic) to end up with your finished surface above the line, at least 21mm tall, preferably 22-23mm tall. Any less that 21mm and you will be pushing it! When putting in the memory card into the case base, position it lower than I did (I rested the memory card on two plastic beads - don't do that, make it lower in case).
As mentioned also in my guide, the two case halves close very well, but expect to do some light sanding when done, and both halves are closed and screwed in place, to get the two halves to close quite seamlessly. Naturally, if you oversand one case half and undersand the other, the two halves cannot meet perfectly as the surfaces are curved, and designed to meet just above the lines marked on the case blanks.
As I PM'd stephen0205, the enamel paint I used to cover the joystick caps started to lift after an hour or so's play; so replacing them, removing the joystick cap surround and using cloth in its place and also making the shoulder buttons far better secured in place. I should have done that before, instead of doing what I did. Whilst the system was being worked on, I also swapped the select and start buttons over so they are right now. I also removed the d-pad unit and got the "up" working now (only control not working before). Because I used some thicker screws in the perspex to secure the two halves together, I damaged the perspex, so need to repair it. Everything holds together fine, but I want it perfect!
Got the first joystick and shoulder button replaced, will do other, and the perspex repair, tomorrow and will update my thread when done; along with this better method.
I have spent time getting my custom project room completed, will upload pics of it in "show your workstation" thread in Forum 42 in the next days too.
Decided, after playing some more Red Alert 3, to do that "cyborg" project I started November and get that done, then do an N64 in my system case - as mentioned before, XCVG, I will call mine "iNto64" - taking the "N" with the Nintendo "N" and "64" too - so if you want to make one, don't use my naming system please!
After that I might try and make an N64 system virtually the same size as the PSone screen itself - probably call it "N64Cube" - you will see why...
Got my Turbo Grafx today with a couple of games, not tried it yet. Board is about 2.5 times the size of my case, but I intend to see if I can do a lot of relocating parts and board trimming and rewiring to make it small. I don't think anyone else has made a small Turbo Grafx portable yet? (BTW -
which forum here will the WIP go into - it is a dual 8 bit system hence considered as 16 bit system). I also want to make a Retro Duo into my system; etc - lots of lovely project work to do in the next months!
It needs a lot of work and attention to ensure everything fits, looks nice and works; especially in cutting the holes properly and spraypainting properly when done - rush this and the case will look crap. No rush, take your time - if you rush, the result will look poor and the system probably won't work! 
WOW! that kits looks good! and professionally done! good job Master Bacteria 
