This was a pic from the video - the parts on the top are a small fan to draw hot air out of the system, an on/off switch from the DC as it can handle up to 3 amps ok, two 2P2T switches to change function of the small 4 button set on the front of the case between volume and contrast for the screen, and as a shifted dpad for playing Q*bert. Larger vent holes at the bottom of the case to draw air in, thanks to convection, and also the processor fan drawing air in, and the DC fan drawing air in and around the rest of the system.
On the bottom are the headphone jack (green) and a recharge jack (yellow) to recharge the li-ion batteries.
The shoulder buttons are in place.
The buttons are wired up, and the perspex sheet made before in place. That is the case front near completion - just needs wiring to the console board.
I had intended to put the controller board against the side of the case, top or bottom, and it would be fine - fine but fiddly. It would also restrict making the case stronger later.
The alternative, is to have the controller board on the top, where the batteries will go - there is just enough space for this to work.
This means I only had to trim one side of the controller board, not both; nevermind, done now, just need to wire it back again. The other part needed trimming anyway as it would not fit otherwise. The offcut (joystick area, etc) was trimmed a little, to fit.
This was to give the idea of how it would fit, so can be wired properly.
There is space for 4 sets of 2 amps 7.4v Li-ions, giving a total of 8 amps, however I may well go for 3 sets instead (6 amps) as the weight will be more evenly balanced, and cheaper (each battery pack costs about £9.50).
8 amps would power the system for 3 hours, 6 amps for 2 hours 10 mins. The system will be quite heavy either way as the actual DC console parts are heavy.
2 hours 10 mins playtime is quite reasonable for sure, however the prospect of 3 hours with one more battery pack is tempting.
Normally, I would open up the Li-ion packs, however might not need to this time, which will save time and hassle. Opening them up is useful if you don't have space to put two cells next to each other and need to separate them and wire them together remotely (NB - a 7.4v pack contains two 3.7v cells).
Here are the choices, I not only need to decide 3 or 4 packs, but also if 4 can be accommodated when things get assembled.
or
