Display enclosure Main lower part Front of display The various parts sprayed black

I made most of the structure from copper-clad board (the stuff normally used for PCBs) as it's rigid, easy to cut and solder together. Originally, I suspected I'd need to use brass angle along the seams but it turned out that a good run of solder alone is strong enough - just need to make sure the angles stay true. I etched off the bulk of the copper to reduce the weight - it didn't make that much difference however (less than 10%). A little epoxy filler was used to fill in the gaps and the whole thing was sprayed with primer and black paint. In some places I used 2mm plasticard (HIPS) and polystyrene cement but I kept this to a minimum for several reasons. 1. The glued seams were noticable even after spraying, 2. The spray paint peeled away from the plastic easily - even after keying with Scotchbrite pads and using primer.. 3. The plastic charges up with static electricity readily - obviously not particularly desirable.

The dimensions of the case were mainly determined by the keyboard. I used a compact laptop style keyboard which I'd bought off ebay a while ago (approx 29 x 14 cm). Its original housing was removed and adapted to suit and some of the "quick function" buttons were desoldered to make way for a small PCB with my power/reset/NMI buttons and status LEDs. (Aside: I had implemented the PS2 protocol on the mainboard for communicating with a standard PC keyboard, but of course when I took the mini-keyboard apart I had direct access to the key matrix. I could've therefore made a custom key scanning system if I'd wanted to).

The PSone LCD display which I was using has the controller board mounted behind the TFT module, meaning a thickness of at least 1.5cm for the laptop's lid. Internally it was just a matter of creating some mounting pillars for the TFT and PCB and making sure the holes for the brightness/volume buttons were in the right place! The speakers from the original PSone unit were used without much modification - some pieces of spare speaker grill were cut to size, slightly bevelled and glued into the rectangular holes I'd cut (some thin bezels hid the edges on the outside).