The shell was NOT big enough to house a Pi3 (slimmed), composite screen (HDMI was out of the question), power source (RetroPSU), lipo (ended up with a 3000mAh) and Arduino tapped into the original controls all at once without any modding. So I came up with the idea for a spacer, which I 3D printed countless iterations of until I had it pretty much perfect, then CNC'd it out of a sheet of ABS I picked up off Amazon. The customer has a friend who paints cars for a living and is going to do all the body filler, cut off the hinge brackets and paint it a really cool color scheme, which made me really happy because I don't trust myself with body filler on this small of a scale. I'm proud that I used a minimal amount of hot glue and 3D printed a LOT of stuff for this and used super glue and epoxy wherever possible. It plays really well and I am glad it's done. Would I build another? Absolutely not.
Parts List:
4.3" composite LCD (backup monitor)
Arduino Pro Micro
RetroPSU
3000mAh lipo (Amazon Uxcell)
GBZ Audio Amp
3DS Speakers
Uxcell headphone jack
16GB SD Card
3D printed screen surround / bracket
CNC ABS spacer
Various 3D printed brackets to even out height
Here's my sporadic photo build log
The ABS Spacer, freshly cut and sitting on my work desk
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