OK, so I made some changes in my plans. Instead of a nanokey mod, I'm going to do a nanokontrol mod. 8 sets of chords (3 arcade buttons, a pot and a slider each) + 1 scene button + 1 master volume + 1 extra knob sounds like a pretty rocking midifighter 2.0 to me.
I plan on making it in a solid wooden box with an aluminum faceplate.
Solid wood means take a big log (I live in canada, they're everywhere) and saw it to length. Then I'll take some off each side so it looks like a solid wood rectangle with bark on the skinny long sides. Then I'll whittle the bark off so it looks like a hilarious log cabin. Hollow the sucker out with a band saw and us a router to sink the faceplate in. I think I'll cover it with some sort of plastic coat so the water doesn't get in or out and cause the wood to crack (my main concern). It's like a Canadian version of the livid boxes. I'm still trying to think of a logo that I can wood-burn into the face.
Face plate: Going to a machine shop is expensive, so I'll see if I can do it at home. My dad is a heavy duty mechanic and has all kinds of fun tools. I'm sure I can use a drill press for the arcade buttons, but for the sliders and pots (which I'll just trace off of the original plastic faceplate, no need taking the faders off of the board) I'll have to use a dremel I think. It still shouldn't be too bad, the only thing is wear a full face mask because the dremel disks sometimes break, and they'll put your eye out if they do.
I read somewhere else that the padkontrol buttons are just contact buttons, super easy to solder new leads onto. Other than the new buttons (and maybe new fader grips) it should be a pretty straight forward mod. I'll probably make a smaller box for a nanopad at the same time, I think I'll keep it as a dedicated beat box.
I'm choosing nanos because they apparently don't interfere with using a usb hub too much. For me that's a fairly important thing as I use a wacom pad for theremin-type synths, a usb soundcard, a mouse, an Alesis ControlPad, and I'm looking at getting an APC-40.