Glad to hear your updates are going well! Just about done here, too.
I am gonna reprint the plastics on the GD drive insert plastic, I was mostly dialing in my printer when I made the original prints, so it wasn't up to snuff.
Noctua mod is fine, but it needs a 10k resistor between the 5v and tach lines. (It uses the tach line to determine if the fan is running, if it isn't, the system shuts down). In this picture, I added the resistor in the line and made a little adaptor cable, but didn't feel good about the look, so I did go back and just changed the header pins and added the 10k resistor on the DC board itself. Anyway, it works great. I tested the sound difference by turning the DC on side by side with my other stock DC. Night and day difference in volume.
Battery was super easy with the little solder-on battery holder, I just needed to add a reminder for future me that it is a rechargeable battery, so I put a label inside as well.
And for some reason the SD extender doesn't work, so I am buying a new one. I used it for years with my old 3d printer, probably just went through too much abuse.
How’s a Dreamcast look hooked up to an LCD via VGA input?
I can't speak to direct VGA hookup, but the VGA to HDMI converter cables do an ok job, with each brand being slightly better or worse than the next. I would say it is a touch better that the wii with upgraded cables. Everything is clear enough, but it will still produce soft, feathered edges.
The DCHDMI VGA upscaler route is amazing. Everything looks crisp and clean like playing on an emulator, really crystal clear, but on the flip side it will create horrendous jaggies due to the lack of anti-aliasing. It can sometimes be just trash to look at. I understand there is a HQ2x filter option if you do a firmware change, and with the DC, I would think that is the best route to go if you are willing to shell out the cash for the upscaler. The video from the filtered DCHDMI is pretty incredible.
I will probably just eventually be getting a cheap OSSC from aliexpress, All these HDMI solutions are killer on the wallet. $100 to get something that does a fair job out of the box for everything is more up my ally.