So I received my LCD driver board from Wayengineer, and unfortunately mine doesn't work at all, so that's definitely a dead end.
@Shank was kind enough to help me troubleshoot it, but for some reason video just won't show up. So I ordered a composite 5" screen and that's on the way.
This is super random, but for anybody using 3ds sliders, it's worth getting official caps for them if you can. I've ordered two different sets of generic ones. One of them feels like more like plastic than rubber, but do a passable job. The others feel powdery and it's impossible to get any grip. The official ones are really grippy and nice feeling in comparison.
Here is the bottom side of the screw hole feet. I did some sanding, but will do the bondo etc after I put in my fan vent.
I finished up my dual tact switch setup and it feels really nice with the buttons. The buttons actually are able to move around a bit too much in their holes but I don't mind that since painting buttons AND the case usually makes buttons that fit well not fit anymore. (Or stick).
While it wasn't on my original list of things I want, I'm kind of sad I can't get component on a screen under 7". So I've been thinking that a nice compromise would be to have the wii have composite on the 5" but also be able to output component to an external TV. I hadn't really considered outputting video before, but thinking about it now it makes perfect sense because it has a built in sensor bar and can do charge and play. Basically it would be a regular wii, only smaller. It seems like when component is enabled on the wii, composite also works, so I could have both the portable and the TV display picture (although I'll probably add a switch to turn off the LCD and amp to save power).
For component video and stereo audio output, I'll need a 6-pin plug (y, pb, pr, L, R, comm). If anybody has a recommendation for a really small generic plug that has 6 pins, that would be amazing
I was playing with the charge and play feature a bit and when I'm playing, then plug in the charger, the wii freezes. It doesn't fully reset, but glitches instead. I tested with my phone and what is happening is when I plug in the charger, the battery cuts off power for a small fraction of a second. It's not enough to fully power off the wii though which is why it freezes instead of resetting. I ordered a 1000uF capacitor in the hopes that this will tide over the wii for that moment.
I was also examining my ds lite today and looking at how they didn't need to indent the buttons at all. They indented the top screen instead, but it's very subtle (like 1.5-2mm). I was originally thinking I wouldn't be able to do that, but since I now have a test driver board and a screen, I can take more accurate measurements. The way my buttons are indented in the lower faceplate looks really awkward, but looking at what I have now, I may be able to raise them back up to a flat plane. I think this would look much better, so fingers crossed!