You make your own circuit board? I wish I could do that kind of stuff. It'd make my life a lot easier when it comes to modding... I wonder, if you could make a guide using your method? I know it might be too advanced for some of us, but it'd be nice to see how exactly your method works. I'm really intrigued about it and I'd like to at least see a picture of it.
I may eventually, but I'll give a little run down of my process.
I wear gloves when removing the panel to avoid fingerprints. They're difficult to remove, and cleaning solutions usually make the problem worse. Then with a cutting disk and a dremel, I'll completely cut a chunk off of the panel. This usually leaves plastic bits on the panel which can be removed with compressed air.
Then I will glue the custom PCB to the plastic of the shell. My initial plan was to glue the PCB to the back of the LCD and have the ribbon cable fold back and solder to it, but there's no room to do this because the LCD sits flush on the main PCB, so I just glue it to the plastic.