Thought i'd publish it on Instructables. It is entered into the "Gaming" competition, and "featured" in their Play section.
http://www.instructables.com/id/How-to- ... able-Cons/
I would be most grateful if you like what you see, and have an Instructables account, if you could please vote for it - that would be awesome!

Here is the Gaming Competition link:
http://www.instructables.com/contest/gaming/
That is the last vacuum forming case I will make, future commissions will be tabletop design prodominently, I have a commission at the moment for this in fact so over the next weeks I should be posting the one for an N64 system and in a few months for SNES system too.
Here is what the system looks like:
http://bacman.co.uk/n64-commissions/
Such systems do not require the board trimming or level of relocation of parts as needed by a handheld system, and are more robust and also I think, more attractive by nature.