Big-ish update!
First of all, I've sorted out the audio. I think the chips are *Can'tSayThisOnTV*ed up, because I couldn't find anything wrong with my wiring. So I ghetto-rigged the headphones onto the amp that came with my mini speakers and added a volume pot. Boom, stereo and smaller. Only problem is the MASSIVE volume pot. I think I'll put it on top.
I do have a picture of the N64 trimming but it sucks. Imagine a stock N64 board with the front cut off just a bit past the jumper pak slot. I plan to trim the sides too, but not yet. I also have to relocate the cart slot, in place because of the way it's mounted.
The controller board had to be trimmed. You see, it has to more or less fit into the area under the screen. Just getting the little bit I needed was pretty hard. The thing is also crappily made and the traces peeled off like a cheap sticker. But I think I've got it trimmed and working. Though I haven't tested it. It's also wired to two XBOX sticks.
Last but certainly not least, I did some casework. Got the screen hole cut out, should file it some more but it will work out okay at this stage. The joystick holes were drilled with a speedbor/spade bit. The left side one worked great but the right one got a little gnawed. Oh well, I don't want this to get any more OCD than it already is. The d-pad and buttons I attached with liquid ABS. It works great but it's kind of a pain in the ass to make and use. I also worry about the safety of it, as the fumes are pretty nasty. Anyway, the d-pad isn't dried yet and the control cluster has been sanded. On a side note, I need a new Dremel. The lock button on mine is busted so it's almost impossible to change bits, and the motor is on its way out too.
So overall, a somewhat but not overly productive weekend. I was lazy and had just installed some games, so I ended up pissing away most of the weekend.