I've kinda been waiting around for someone to jump on this challenge since all the new innovations in GC portablizing have come about and since Zenloc showed that the GC motherboard can fit. Since no one has yet so far, I am going to, just to say I've done it. I've done some extensive measuring and with my GC motherboard clocking in at exactly 70mm x 104mm I'm pretty sure I can pull this off with very little case modification IF I let the heat sink and fans stick out the back of the case.
This is the case I've ordered from DX.
I pretty much have everything else I need for the build here already except for the case.
Features, Parts list, Plans, Etc:
OMGWTF Cut GameCube motherboard
Stock GC heatsink trimmed to 1cm with 2x Tchay's 6mm ebay fans attached on the back running @3.3v.
Wiikey Fusion
4.3" Screen Its the same one SS is using for his portable. Its nearly a perfect fit for the PSP case. I'll have to relocate some junk on the driverboard to make it thinner and also trim the sides a bit to make it only as wide as the screen.
Phillips mini audio amp
Switching headphone jack
Original PSP mini loudspeakers
Zenloc's 7.4v custom regulator (3.3v and 1.7v)
2056 Memcard (Slot A)
SD Gecko (Slot B)
GC "classic controller" style controller for the driver board. This means I sacrifice rumble, but if you've ever seen one taken apart it can pretty much be cut right down to the black blob that controls everything. Meaning its REALLY tiny. I may also utilize the shoulder buttons from this. Probably not though.
Obviously the PSP case is to small to house any significant amperage battery, so an external 4000mah 7.4v pack will be built. Hopefully I can keep the amp draw of the whole system under 2 amps, then I could use a PSOne power supply to power the whole thing.
The plan right now is to keep the front of the PSP case stock (besides the need to add a spot for the "C" stick analog) and the back, sides, etc. as stock as I possibly can within reason. That means using all the original PSP buttons, dpad and the shitty PSP analogs for both analogs. I'd like to cut apart a controller to retain the "squishies" for all the buttons but I'll have to see what I have room for. L/R will most likely end up being digital only. I'll try to retain the pots if I can though... somehow or another.
Progress so far:
You can't really see it in this pic. But the GC motherboard is sitting beneath the screen:
Everything is all wired up and working perfectly. Wiikey, Player 1 controller, Memcard Slot A and SD Gecko Slot B
Took a page from Zenloc's book and made up a memcard adapter for slot B (gecko slot). Working nicely so far.
Started wiring up my controller board. Tested what I've done so far just now and all seems to be well. I've sucessfully wired the rest of it without screwing it up. SD card shown for size comparison.