Once I got to the laser engraver, I cut the parts out of mostly engraving plastic and .25" acrylic, as seen below!
Well, in that shot it's actually cutting a different portable but you get the idea. I then stacked the acrylic pieces to make case portions .75" high. Superglue and expoy hold them together. Well, that and love.
Here's the cartridge connector and NOAC inserted in the rear portion of the case...
And here's the front half of the case. If you look closely in the upper left, you can see where the battery terminal goes directly to the power switch. I had to move and rewire some of the biggest capacitors off the front of the TV board and move them to the back so the TV board would lay flat enough for the NOAC to fit. Oh well, it was worth it!
The NOAC is securely taped and hot-glued to the rear portion of the casing and battery holders were hand-cut and super glued into place, as seen below.
Here's the unit open with both halves. There's actually only about 8 wires going between them - +5 volts, ground, audio, video, latch, data, clock and a battery terminal link. You can practically count them in the photo.
On the sides of the unit are plastic bits that you pry open to find the batteries, as shown above. I knew the batteries would fit, so I just left space for them in my designs. Then, once I actually assembled the unit I hand-cut spacers to hole them in (seen just above the batteries on the screen side) I've found it's a lot easier to cut certain things by hand while assembling the unit than try to design every little widget you might need on the computer.
Here is a size comparison photo. Yes, it's still bigger than the other units but come on - it takes a whole NES cartridge!
And there it is - the complete story of how I built my NOAC portable Nintendo 8-bit! The Super Joy Fun Stick Player Mech Game Player Game has risen from the ashes of its cheap rip-off Nintendo 64 controller shell and emerged with new life!