01.10.09: thanks for the feedback - i might just have to keep tweekin'. a couple of responses..

re Being bulky: the overall size is not much bigger than an original. I've removed/sanded the outer case just to keep this structural bits for screens, mother boards etc. BTW: It's been lacqured - so no splinters.

Playability: good no real difference except if you dont know which are the ABYX. and yep, the shoulder buttons are screws (a bit of a copp-out, i know, but after a year, I needed it off my desk!). will look to replace power/volumes sliders with something a little more fitting.

and definitely, 1 or 2 valves/guages would be sweet.

30.9.09: for anyone whos interested, here's the result of a few hours work. Finally completed a Steampunk DS Lite. Made from Cuban Cigar boxes, comes complete with authentic Republique De Cube certificaiton sticker, Mother of Pearl directional pad, stainless A, B, Y X buttons. just in the process of making a bone stylus.

this was the result of dropping and busting my DS. Had to replace the top screen nd microphone - thankfully the Microphone they sent was this sweet little brass number - fate!

you can have a look here:
http://www.steampunk10.net/2009/09/steampunk-nintendo-ds-lite.html