Keep in mind that I made this case a couple of years ago and it was my first experience with bondo, a dremel, and making a portable so it all added up to one ugly case. In fact, it is beyond ugly. It's... fugly.
YouTube video link
And now for the obligatory pictures that inspires millions to go and build portables for their very selves!



I drilled the speaker holes free-hand. No measuring!

Before wiring



Traces scraped, fluxed, and tinned ready to be soldered to



After wiring




Here's the kicker: I measured what it was drawing and the whole system only takes 169 mA at 6 volts to operate! That's hours of gameplay off of only 4 AA's! I feel warm and fuzzy inside

The screen is a "Zate" 2.5 inch LCD screen I bought off of eBay for $60 total including shipping. Why use that when Hip Gear screens are so much cheaper? Well, had I used this one to begin with I would have saved a butt load of money in the long run. It's the same screen I mention in this thread. I have a second one I plan to use in a super-light SNES FC Twin portable that might possibly only need 4 AA's to run.