Quite an update on the briefcase. I spent a while thinking how to do this, to make it look reasonably nice, securely hold the console in place yet be easy to remove it. I decided to build a skeleton out of polystyrene (left over a while ago when we got a new freezer for the garage!).
Working out where the console will fit in the briefcase:
The polystyrene:
I cut out four corners so the console fits nicely, and can be removed from the sides or top:
I used some old cloth table napkins spare, one was cut into four pieces so covered them fine. I used hot glue to glue the polystyrene to the cloth (you can't use normal glue as it melts polystyrene):
Done. Hot glued them to the case:
Thought this looked rubbish, and also it wasn't secure, so I cut out some mounting board strips and hot glued them between the polystyrene parts:
I then put another table napkin over the top, put the console on top, when I was happy with it, I took off the console, drove some heavy duty stapes through the construction in the corners to keep everything in place and hot glued the material in place to the sides where needed.
Put the console back:
As you can see, there is plenty of space to lift out the console from the sides (or top and bottom). It doesn't have to look taught, it is nice to have looser material, looks nice.
When I make the holder for the carts and the PSU (not with polystyrene, I used this before for the console's height), I can cover them with the napkins, to keep uniformity. As to the corners of the parts above holding the console in place; if I put some mounting board on top and secure this into the polystyrene with nails, I can glue a napkin to the tops and make it look smooth!
More work to do to finish this, but you can get a feel for how it will look when finished.
I anticipate being able to house about 16 or so N64 carts in the briefcase; about a fifth of my N64 collection.