On reassembly, I did have an issue with the analogue stick. It turns out I had put the "d pad" membrane in the wrong orientation, so it was pressing the Analogue stick and the PCB below apart. Once it was rotated, it worked fine for me! I thought the pogo pin idea was a good one, but if it doesn't last, it's no good!
Now it's all back together, I may look into getting a SD apater for it, the 4GB memory card is only going so far!
It's a great console, and I am enjoying the games that came with it all over again!
I was always very impressed with how modular and repair-friendly the PSP was... with one exception. If you ever opened the thing up, and especially if you replaced the outer case, the analog nub was likely to never work again. It had no ribbon cable or wires and relied on being physically pressed against the motherboard pins in exactly right place to function. Even after replacing mine 7 times, I could never keep it working for more than 2 minutes before it internally shifted out of place ever so slightly.
The UMD door was never seemed to fail for me, but that was probably because I almost never opened it.
I used an SD adapter for the memory card to store games, which also provided faster read speeds. You can still get these adapters for about $6.
Fun fact: It's GPU also included support for NURBS rendering, which is like using curved vectors for 3D shapes instead of polygons. Very few games used that feature though.
Overall, I always felt that the PSP had a near perfect and timeless physical design. It fits perfectly into your pocket.