Yet more messing about with the design but I think I've finally roughed out how the front panel layout will work. I think it'll look decent so I've quickly (ha!) printed one off to get a feel for what it's like in the hand.
Printing time is quite long, so iterating the design is slow even when broken down into separate modules.
Generally it looks like things will fit easily. In fact I think I'll do a version with two buttons on the left and a third on the right. You almost want four buttons for Android though as you've got 'select', 'back', 'home' and 'task list' so this might force me back to using the trackball to select things.
I'm also going to have to face up to the fact this 'quick' build won't be ready for the LARP this weekend. I could rush it and have a version made up but it's actually a bit too physically large to act as the 'covert portable terminal' that fits what the character needs. So I'm probably going to stick some spray paint on an old Sony Ericsson Xperia X10 mini pro, which is an ancient Android handset with slide out keyboard that will work just fine as that prop.