Anyway, here is the GBC. Instead of destroying my good GBC, I put the PCB into a different case that is in nicer condition and have opted to use this purple case for my project. My goal is to fit a 3.5 inch screen in there along with adding X, Y, L1, & R1. I've opted to do some case modification using "JB Plastic Weld", using the buttons and templates from a DSi. I plan to use "soft" tactile buttons for the d-pad and face buttons, though this might not work due to size constraints. I'm going with USB audio and GPIO buttons. I currently have an 2500 mAh battery that is pretty large, so I might look for something smaller.
Getting on with it, here is the original Gameboy Color. The pictures don't show it well, but there are a lot of scratches/chips on the shell along with the protective screen being very damaged. However, as is expected with frankencasing, I will be doing a lot of sanding and also painting, so these scratches are not an issue for me.
Gameboy ColorShow
After I was satisfied with the screen, I went on to buttons. I took all my buttons from a busted DSi I came across. Unfortunately, these buttons are designed to work with those tiny tactile switch membranes that are directly on the DSi PCB. I'm planning on using some "soft" tactile switches I have, but I have a suspicion that the button layouts might be the same as the DSi so I could possibly use the rubber pads. The start and select buttons will be standard tactile buttons. As I'm likely making my own PCB, I didn't want to have to mess with making such a small conductive pad for the relatively small original rubber pads.
Case Modding [FRONT]Show
NOTE: The screen is a broken one from my first GBA try that didn't survive disassembly. I'm using it for size testing
Next on my list will be to do some cutting on the back of the case. I plan to cut out most of the battery pack. I don't think I'll need to do too much more to it other than figure out what kind of L/R buttons I want to use.
After that, I'll use the JB Plastic Weld to set the buttons in for the first time. Due to the width of the screen, some of it is now seen from the outside (as the volume wheel, EXT port, and power switch are indented). I'll have to use some of the plastic cement to fill those areas in and make the case look flat/smooth. Then the sanding and re-applying begins. I believe this step will take me a few weeks, due to the time it takes for the cement to cure and how much of a perfectionist I am. Another problem for the future is that I've managed to remove every screwpost from the front, so I'll have to remount all of those once the screen and button PCB are in place.
I've got most of the parts available. I really struggle with doing button pads so I don't know how long this project will take me overall, but I really want something smaller than the original DMG but I also want 4 face buttons + 2 shoulder buttons. I've basically already gotten my screen/pi/power strip/powerboost set up, so once the case is "complete" and painted, I can start mounting stuff and worry about audio and buttons.
Super wordy but any advice would be greatly appreciated!