Skyone always says, "You should submit this to the showcase
About the expansion port, tear that Sega off, and bend the pins from the cartslot over. They reach the little blobs of solder, making it thinner
then, cover with electrical tape and flood with hotglue.
Hmm, that's an idea, but if I did that I would do it right and solder it. I don't want to go back and redo it, especially if it's covered in hotglue.
Just get a sheet of 3mm plexiglass at the home depot. I am using it for sheet plastic on my portable. Just sand the shiny gloss layer off (I did it with 1000 grit, so it can't be that thick.) and paint it with Krylon Fusion. Looks just like regular ABS plastic, which is good for $2.49 a sheet.
I'll look but I'm probably going to use the N64 case, a la ShockSlayer.
Also, anyone have any tips on how to obtain free samples from TI?