I chose the DS Lite out of the others because I believe that the 3DS and DSi shells (even the XL) are thinner than the DS Lite, which would make it a lot harder. And the original DS wasn't exactly the best looking
Basically my thinking is, it would be impossible to keep the display in the bottom, so that would have to go. The speakers and display would be in the top half, everything else down below. What I think is pretty cool is that you could even keep the original screen protector in the bottom, so you could look in and see the Pi Zero at work (if it looked pretty in there ) The amplifier and low-pass filter might fit up top as well? In any case, you probably want to limit the amount of wires that go through the hinge to as little as possible.
The hardest part about this project aside from the limited space in the bottom, would be routing wires through that hinge (for both speakers and the display). Maybe the display's ribbon cable could be routed through a slit in the hinge, then tied down to the control board in the bottom half. I doubt the display board would fit in the top half, it's pretty thin up there.
Not that there is much room in this shell anyway, but it would be cool if the original cartridge slot right underneath the hinge could still be used to insert an SD or micro-SD card and wire that up to the Pi Zero. Just food for thought.
Battery placement would be very limited, but perhaps the original 3.7v one might not be a bad option at 2000mAh. It sits beneath the D-Pad.
- Length: 133 mm (5.2 in)
Width: 73.9 mm (2.91 in)
Height: 21.87 mm (0.861 in)
For those interested, you can purchase a replacement shell from eBay, such as this one direct from china, which seems to include everything you'd need.
I'd love to hear what you guys think about this potential headache of a project.