PortabilizeMii was the predecessor to BBLoader, so just replace any mention of PortabilizeMii with BBL pretty much. VGA patches refers to software on the wii which allows the wii to output vga signals, you can set it up when installing bbloader as it's bundled in.
Yeah, I don't see 1mm being enough tbh, might have to up it to 2mm in parts. It might be alright if it were CNCd aluminum but that's not the easiest thing to make...
Ooh that's a really nice colour scheme. I like the mesh you've used over the vents, looks clean. For your buttons are those printed SLA or FDM, or did you cast them separately?
Those traces don't go anywhere, so you're likely okay. The scratches may cause shorts between the voltage lines, you'll know if you check all voltage resistances like here:https://bitbuilt.net/forums/index.php?threads/wii-trim-resistances.2602/
I don't belive they work natively with the pms due to the slightly differing voltages, the frimware needs to be modified slightly. Gman knows more about it, but don't wire them in until you get the go ahead.
Yeah, sandisks don't work well with BBloader due to the bad structure of them. Best is the kingston micro SD to USB adapter and a Samsung micro sd. You can get the adapter on the BBstore, but it's also available on amazon, ebay etc...
Issue is most people aren't comfortable selling until they're very experienced, so not many actually sell. You'll have more luck searching for an n64 with cartridge support, since that's more common. Gman actually recently completed one
Only person I know of that does PS2 and N64 for commissions is Gman, not sure how active he is on Instagram, so you can either try DMing here or on Discord. He's pretty active in the BB discord server as well.
I can't legally tell you where to get said games, but all games should work dependings it's assembled correctly. There are a few cases in which they won't work but that's inherent to portables. If you're commissioning a well known memeber they'll be able to tell you whether all game will work or...
Running off a usb or sd is functionally the same as a disc, it will run perfectly due to it being the original hardware. With a usb you can have loads of games available at the same time, without having to find discs and such. The only thing to learn is where to get the game files. A portable...
If you're looking at making a portable make sure your wiis are 4 layer and not 6. Practice soldering on old junk electronics and you'll get the hang of it. If you want a easier project you could try a wii micro so you don't have to worry about batteries, display, and controls
No you don't need the protection, pms handles that. Balancing isn't necessary for parallel confiugurations, it does it on its own, just made sure the cells you use have the same voltage - if not charge them all fully and they should be the same