I've had to take a pause again from working on this due to the day job, but quite a bit of progress has been made which I will detail in a later post. Just wanted to throw in an update of one part:
I want the USB ports to float in the controller ports like the original. So I designed and 3D printed some inserts. The printer I used was a Cube 2 printer (I don't recommend it - thankfully my work paid for it, not me!) They required quite a bit of trimming to fit properly even though I triple checked my measurements due to the inaccuracy of the printer. They are designed to snap into the slots on the sides of the controller port for a tight friction fit.
I am going to be redesigning these to have more of a floating look and hopefully a better fit. I plan to accomplish that by having only three points the length of the USB connector. I will post up the files for it once I get them just right for anyone wanting to do the same.
I am also planning to design and print a bezel for the lens on the front, but I am actually considering doing a chemical etch of some copper sheet for that instead.
Several other custom 3D printed parts are also in the works.