glad it’s coming along. It looks fun 
truckbed coating is good stuff. haha once you use it for something you will see how durable it is and likely find other things too at some point to use it for lol. It really is a versatile substance! Fire and forget! I find for something big and heavy (like a PC case, that weight 10+ pounds) it’s ideal.
for a console the rugged feat of TBC may not be as important, but you will never have to worry about flakey paint on oily plastics that dont like paint. like I said fire and forget… I wish they made it in a few colors but AFAIK they dont!
Also do note that texture surface. may or may not be to your liking it’s a very uniform texture with no aberrations, etc. I have painted it on super cheap plastic drive bay covers from china so your nes should be safe from any chemical interactions.
texture surface probably is going to catch pet hair a bit. (However, a wipe with a towel is easy enough to clean) a big heavy PC case (with weight) will scuff against things that it comes into contact with like the walls of my old high school, wouldand get white marks on it (you can actually scrape and sand these off).I would imagine something light (and isnt moved about much) it would not happen at all. You coudl also sand the finished thing down if you want a smoother look maybe, i’m sure you could do that i just havent tried it, i actually wanted a rough raw gritty industrial look.
I would think that this thing probably doesnt need any cooling at all. If that’s the case it probably really isnt going to be a big issue with dust or hair unless fans get added. fans will make dust management more complicated. I would say dont do it and just see how it goes without any modding with the fans and no need for a mesh and whatnot and just clean it out with a vacuum cleaner with an nozzle extension, just stick it in the pi hole! I can understand you wanting to mesh that area you mention. Yeah need to come up with something to do with it… You’ve probably thought of other things like windows and maybe slapping a plate over it but rather than a mesh this would also look nice (read comments)
If those holes are too small for jabbing a vacuum into (hard for me to tell, but they might be) or ramming stuff inside it is not really a good idea to your liking, or you figure you will need to open it up and close it to mod the innards time to time anyway. then maybe its best to come up with some sort of assembly plan for top and bottom shells. magnets seem like they would work well for something so small and little stress points on the two shells but i’m not sure where on the NES you could have a magnet type assembly. Maybe you could glue them to those struts the screws came out of? that’s easier than working with those screws themselves if you go in and out of it to mod/clean/etc.
TBC only:
Nothing wrong with that. However, you could use the original stencil you made to make the cuts from (or make a new stencil) and move it a bit to get something like this with what you’ve already done:
I think this looks nice. Your previous project gave me this idea cause you could then go about adding drawings of your own on top, somewhat similiar to what you made last year. You could also do plenty of creative stuff with this stencil idea and use tape and whatnot to make ‘yellow’ designs on other parts of the case, characters you like from video games, etc. though i’m not sure how you’d get good detail on them in yellow using a stencil. best of all all the edges and corners are protected with TBC. so you should be able to get away with it and really never have paint problems of any kind. Seems like it would be a nice compromise.
Hmm. I like this idea of undercoating something in a base color then stenciling on top with TBC… I’m not knowledgable about stencilling but it seems like a real good way to do stuff.