Haha, I too am making a project just like this (wasn't there a 3rd person that posted a similar topic around the time that you did?). Anyways, I've been meaning to register and post my own topic, but work has had me busy for the past month. Just thought I'd drop a bunch of helpful links and advice that I've gathered from my own endeavors.
- To add shoulder buttons somewhere on the device (I am not sure where yet.)
It seems you'll be taking a case-modding approach, so most of this might be irrelevant, but maybe it might spark an idea. I will be doing this too, if only so that SNES games will play on it. For my project though, I'll be trying to keep the original case as untouched as possible (with the exception of lead outs for USB, HDMI, etc). The shoulder buttons, I imagine could be hooked up via an expansion board that could hook into the cartridge slot and hang off of it, giving a sort of "balcony" where I could place them. I might do a similar thing with the +2 buttons needed on the front, but if it's too cumbersome, I'll just stick to using an Xbox 360 controller to play those games.
- To use the cartridge slot to load the SD card, if possible.
There's a guy at this other forum who has built a few portable systems retrofitted into the Gameboy. Amongst them, he did just this: http://www.made-by-bacteria.com/viewtop ... =20#p23845
It looks fairly straightforward to do; just solder the pins wherever you want (can be spaced out like above), and then match them to the Pi -> cartridge slot.
- Does anyone know a way to mold and manipulate plastic? Like, I want to be able to fill the holes on the surface and move them to somewhere else, and smooth out cracks and stuff.
I recommend skimming through Akira's other projects, or even the rest of the forum. There's some good advice as to what products are good and bad.
- To remove as many components from the Pi as I can to conserve space, by directly soldering cords to the board itself.
Ben Heck recently made a Portable Pi, and a lot of what he did can be applied to your project. I recommend watching both parts, but this will skip to the relevant portion: http://youtu.be/dUZjzQuTNX4?t=11m14s
- Now, my main concern is the LCD display. It's the only thing where I have yet to find a suitable part.
Since you mentioned your busted screen - I just ordered one of these after they were out of stock for 3 weeks: 3.5 inch TFT LCD
. It's 640x480 and 3.5 inches diagonally. Reportedly, it operates at 6V - 12V as long as there's a video stream coming in. With a 7.4V Li-Ion/Li-Po battery, you could power the screen and then use a 5V voltage regulator for the Pi (FalconXY did that for his GamePi
). I suppose you could also do the 5V mod posted above by blc, and then power both devices without worry.
- A power source, (Battery, preferrably.) as well as the necessary parts and wires.
I'm pretty stuck on this too, but I'm saving this for dead last. I want to know how much space I'll have when all else is done, so that I can order the biggest battery possible with the highest capacity. I had a genius idea as to how I'll be measuring available space: Legos! Just cram as many as you can in there and then measure the bricks.
Anyways, I'll be posting my own thread up in the near future. I'm also new to hardware electronics myself, but being a fast learner, I know this will be a pleasant learning experience. If I happen to come across anything else, I'll definitely share!