The first time I tried to make an n64 more portable I soldered the expansion pack directly to the pins from the slot it should sit in.
But this is quite hard to do because of the precise removal of the slot and not breaking 1 pin in the process.
Miceeno has some great pictures of this method.
Then I tried to remove the slot fully and solder wirewraping wire to the expansion pack.
This is also quite hard to do because of the n64 is very picky about the length of the wires to the ram chips.
The last option I think is the best because you don't remove the slot you don't solder you just put the expansion pack in the slot without its plastic.
Great render i think from downingsbasement.com
To make it slimmer cut the sides of the expansion pack