thanks to the trend towards sticking everything on one chip, most of the ata/SD interface/etc external chips aren't really necessary--a lot of microcontrollers already have these built in.
If there's people interested in wallwart powered, somewhat large DAPs, well that's actually not too difficult to make. However, if we want a portable device, it's a lot more difficult. I've been looking into DAP design a lot these days, and it appears that the main difficulty for us HF DIYers wouldn't be so much the engineering behind it but the uber-unobtainium required. I've looked at several DAP schematics from the rockbox project, and honestly the hardware for most DAPs is virtually the same--a DAC/headphone driver IC, some power management ICs, display, RAM, and a microcontroller which sometimes has the rest built-in. They differ in the displays used, the casing design, or the interface design (i.e. capacitative touch sensor on the iPod), and the exact ICs that are used. The most difficult part of hardware design for us is most likely the PCB routing and finding out where to get the casing manufactured.
More difficult is sourcing the components which will allow us to make a low-power and small DAP. Unlike our headphone amplifiers, reducing power consumption is something that can really only be done on the IC manufacturer/designer side. If we want our own DAP to compete in terms of performance/size/battery life with the latest generation of DAPs (iPod nano, etc) we would need access to the newest/most efficient microcontrollers, RAM chips, flash ICs, etc. . . which is mostly uber-unobtainium for DIYers. If we just want something like the old iriver H3xx, we're faced with another problem: since we're looking for audiophile quality, and audiophile = uber-inefficiency, chances are, our design would be even less efficient/larger than the old DAPs which lasted only 8 hours or less. I'm pretty certain that most of our current headphone amp designs/DAC designs already use more power than an entire portable DAP.
The LCD screen for the portable DAPs was indeed the most difficult thing to find when I was first researching the feasibility of this project. I finally got referred to sparkfun.com, which sold small color LCDs for relatively reasonable prices (I think mouser started stocking small color LCDs, too, but at $100+ per unit). Now they even managed to get a hold of genuine PSP LCDs at what I'd say is a pretty reasonable price--they're absolutely the best source for diy uber-unobtainium I've seen on the Internet. Hopefully, should we try going forward with a DIY portable dap, they might be able to help in finding the rest of the uber-unobtainium.
What I think might be able to allow us to make a truly portable, competitive DAP is with a lot of CS trickery. If we've got any EE+CS geniuses around here, I've got a couple of (possibly impossible) challenges for you that could really make a truly revolutionary DAP:
a) get a FLAC/MP3/shorten (shorten seems to use the least processing power, at least on the x86, iirc) decoder to run realtime on a 16-bit MSP430 chip, possibly running in parallel (these things can run literally ~300uA/2.2V at 1Mhz; at higher speeds it's still pretty darn low power)
b) use a more complex microcontroller and instead of mathematically decoding everything, see if you can pull it off using lots of lookup tables. This theoretically could significantly reduce the clock speed and power required. There's a lot of problems with this, including ram timing, what kind of memory to use, etc. . . but philosophically it just kind of appalls me to think that our computers have to recalculate the same basic functions over and over again
hm... I really like making looooooooooong technical posts, don't I?