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notable changes:

designed around a different set of components
modular = easier to modify (e.g: just change the switch carrier if your using different sized switches), and easy to design new side-wings
body usable stand-alone
more ergonomic controller pad/sides (curved backside)
as few screws visible as possible (only 4!)
covered usb and ethernet ports; hidden behind separate flaps

BOM:

watterott 5" touch display
short hdmi and micro-usb cable to connect the display-driver with the raspberry (both trimmed to length)
alps 4-way navigation switch
colored switches for A B X and Y (reichelt.de : "DT 6 RT", "DT 6 BL", "DT 6 GE", "DT 6 GN")
tiny tactile switches (reichelt.de : "Taster 9302")
pieces of ~1mm diameter wire for the shoulder-button and rear-flap axle
countersunk M3x10
optional: self-threading screws to secure the switch-carriers and the tft bracket

Assembly:

parts that need to be glued together:

body_backplate + body_backplate_sliders (mind the slanted edge on the later, they go topside-on-topside)
body_frame_*
body_tft_* + pody_raspberry_support
body_rear_base + ODD numbered body_rear_*
right_button_carrier_*

other:

the even numbered body_rear_* are inserted inbetween the odd num bered, with a straight piece of wire as the hinge
sand; paint; enjoy :-)

Raspbian as base OS
Retro-Pi, installed via the setup script
which in turn gives you emulationstation as UI
adafruits retrogame to hook up the push-buttons directly to the gpios of the raspberry

the body frame is designed to be slim, so the pinheader pins 1-10 had to go :'-( (either desolder, or trim them... or design a backplate with a bump in it)
batteries not included - at least not yet, there is still room though

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