I ended up wanting to make several changes to the original, mainly adding adding the ability to use the HDMI port and headphone jack on the raspberry pi. After some searching, the closest that I could find for someone doing this was a reddit thread that pointed to a dead or since deleted remix, and an STL that was based off of the old version that required screws for the case. Since I wanted the case to snap together like the newest model, I ended up completely re-creating the entire case in Fusion 360 using the older STL as inspiration. Thanks to stiltonfondu on Reddit for posting it and his images showing this could work.
In order to have the HDMI and 30mm jack on the top, the pi and screen had to be rotated 180 degrees. This also created a problem with the ribbon cable as it no longer could run in a straight, flat path to the buttons. Thankfully the cable was more than long enough to wrap around if the wires were carefully separated (no shortening of the cable required!). I also made the entire body slightly longer in order to easily fit the battery and all the wiring. Closing up is now a cinch.
After messing around for too long with the audio issues that seem inherent in this build, no hardware fixes that I tried other than adding a ferrite bead to the audio wires coming off of the PI seemed to make any difference (and even that seems minimal). As a bit of a half measure, I added a "mute" switch to the bottom so I can turn off the speaker if I want to use the headphone jack (which doesnt suffer from the same problems) or play in silence.
Lastly I applied a layer of XTC 3D to the case. Having never before used it, I was not sure what to expect. After wet sanding down to 2000 grit, the case feels amazing in the hands and looks great! The buttons were sliced in 3D builder in order to print with different color filaments. The bases or all the buttons and D-Pad are printed in TPU, while the button tops are printed in various ERYONE silk colored PLA filaments.
Thanks for the great project! Now excuse me while I go relive my 90's gaming glory made possible with all this wonderful modern tech!
0.4 nozzle/0.2 layer height
eSUN 3D PETG