The varnish was nice and dry last night, I let my wife have first play on it. I inserted an N64 cart into the system, Banjo Pilot and she had a play on the console for a few minutes. She was very impressed (not bad as she was indifferent before). I then switched it to GBA and played a few games of Galaga and Ms Pacman (Namco Anniversary), whilst I was sat down. The console sits nicely on my legs, console feels really comfortable to use, and natural to use; isn't too heavy and is evenly balanced (unlike the BigBoy Advance which was top heavy). I am really happy with it, in terms of its looks and playability. I need to hold the case differently when playing N64 games (joystick) and GBA (D-pad); feels great either way; just as designed. This was the proof of the pudding, after four months work on this project.
The fan is completely silent now it is inside a case, I get a very light breeze from the fan exhaust, shows it works fine. Sound quality is excellent.
Only a few very minor gripes (nit-picking here):
* Some light from the PSone screen goes into the top of the case, so I can see the supporting struts through the case front; not a problem, looks quite nice actually, like a night-glow; I can solve this if I need to with a layer of BluTak to block out the light leak at some point if I have to remove the case.
* D-pad only works on GBA, this isn't important as I only like to use the joystick on N64 games anyway. No issue.
* I snipped the GBA Menu button wires - only relevant with the M3 Flashcart anyway, and that is if my next one to arrive works ok. I can access the menu easily with four button presses anyway. Again, if I open the case up at some stage for repairs, I can rectify this. Not an issue though.
* I made a small scratch on the inside of the case on the window when I was filing the sides of the case down, can barely see it and not when a game is playing (unnoticeable).
* The screen window is a bit cloudy from when I removed the spray back from the spray paint a while back, not noticeable at all when a game is playing (invisible, so not an issue).
If I had really damaged the screen window I could have made a new window, as it was, I didn't have to.
These are really really tiny points to make, just me being a perfectionalist, that is all. I have made the case really solid, robust, attractive (I think so anyway), comfortable to hold, buttons in easy places to get to, enough space at the rear for my fingers to rest; and quite easy to open to get to the system guts.
I just need to cut out the five small circles and stick them with hot glue onto the tact buttons, then all is done and I can post final pics, and vids (hopefully, if all goes to plan).