Well everyone is either using an after market case or the original one. Both are too fat for me. I wanted something slim.
I was interested in making my own from the start. If you consider the costs for the tools then things go overboard quickly. Cardboard is easy to source and to sculpt. The only disadvantage is that the case is sealed. I cannot modify the components once its all put together. An alternative would be to use screws and screw wells rather than glue to attach the back plate. Might try that too.
The only missing components are headphone jack and pwm audio circuit which i am looking for.
Have you made a GBZ? Can you link it here?
i'm actually still in the process of sourcing parts, so far all i could link you to is pics of the few things i got in the mail so far. and i get your "too fat" perspective, but for me this entire project is all about taking an absolute cornerstone and icon of my childhood and transforming it into something magical, something 7 year old me would not have believed... with a generic handheld case or a bunch of cardboard i just won't get that, i'll get a highly functional and impressive piece of tech but the nostalgia is gone. i thought i would use aftermarket cases as well, but i got 2 in the mail today that look so off that i actually started bidding on broken original gameboys on e-bay. the original dmg gameboy is so close to my heart, i could never build this inside anything else, no cardboard, no game gear, no psp, no ridiculous game grrrl (so ugly), not even a gameboy color or pocket will do. sorry for going off on this rant, but it is true: the original gameboy has a place in my heart more special than any other hardware i had contact with during my lifetime, imitating it in cardboard just seems wrong. to me. i am not trying to diss your idea, i think every new thing this scene comes up with is good because it shows people are creative and might even trigger more creativity in the people seeing it, i'm just saying that to me it misses the point of the project. to me. very subjective.